CN116352607B - Centerless grinder compensation control system and method based on numerical control analysis - Google Patents

Centerless grinder compensation control system and method based on numerical control analysis Download PDF

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Publication number
CN116352607B
CN116352607B CN202310327117.XA CN202310327117A CN116352607B CN 116352607 B CN116352607 B CN 116352607B CN 202310327117 A CN202310327117 A CN 202310327117A CN 116352607 B CN116352607 B CN 116352607B
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trimming
size
grinding wheel
workpiece
compensation
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CN116352607A (en
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薛燕舞
张宏兵
任惠平
吴亮
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Wuxi Mingxin Cnc Grinding Machine Co ltd
Wuxi Mingxin Machine Tools Co ltd
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Wuxi Mingxin Cnc Grinding Machine Co ltd
Wuxi Mingxin Machine Tools Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B51/00—Arrangements for automatic control of a series of individual steps in grinding a workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B41/00—Component parts such as frames, beds, carriages, headstocks
    • B24B41/007—Weight compensation; Temperature compensation; Vibration damping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/02—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent
    • B24B49/03—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent according to the final size of the previously ground workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/02—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent
    • B24B49/04—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent involving measurement of the workpiece at the place of grinding during grinding operation
    • B24B49/045—Specially adapted gauging instruments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/16—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the load
    • B24B49/165—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the load for grinding tyres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B53/00—Devices or means for dressing or conditioning abrasive surfaces
    • B24B53/017—Devices or means for dressing, cleaning or otherwise conditioning lapping tools
    • 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]

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Constituent Portions Of Griding Lathes, Driving, Sensing And Control (AREA)

Abstract

The invention relates to the technical field of centerless grinding machines, in particular to a centerless grinding machine compensation control system and method based on numerical control analysis, wherein the centerless grinding machine compensation control system comprises a workpiece size measuring module, a workpiece size dispersion analysis and feedback module, an edge trimming grinding wheel trimming execution module and an edge trimming grinding size compensation feeding module; the workpiece size measurement module is used for measuring the size of a workpiece at the discharging position of the centerless grinder; the workpiece size dispersion analysis and feedback module is used for analyzing and evaluating the size dispersion of the workpiece in the evaluation period; the edge trimming grinding wheel trimming execution module is used for starting the edge trimming grinding wheel trimming execution module to perform online trimming on the grinding wheel when the defect of the grinding wheel is aggravated in the grinding process of the workpiece; the edge trimming grinding wheel trimming execution module is also used for transmitting trimming state data related to size compensation to the edge trimming grinding size compensation feeding module; the edge trimming and grinding size compensation feeding module is used for performing size compensation of edge trimming and grinding on a workpiece being ground.

Description

Centerless grinder compensation control system and method based on numerical control analysis
Technical Field
The invention relates to the technical field of centerless grinding machines, in particular to a centerless grinding machine compensation control system and method based on numerical control analysis.
Background
Centerless grinding machines are widely used for their high precision and high efficiency. The most commonly used grinding mode is through grinding. The cutting amount is generally large in the rough grinding or semi-finish grinding stage of the workpiece, and the grinding wheel is severely threshed. With the continuous wear of the grinding wheel, the dimensional accuracy and surface quality of the workpiece continue to decline. To restore the grinding accuracy of the workpiece, the usual method must stop grinding the workpiece and then finish the grinding wheel. And after finishing the grinding wheel, continuously grinding the workpiece. Because the grinding wheel is threshed quickly, the grinding wheel must be continuously dressed due to the blockage of grinding dust and the like, and the dressing interval is also short. In addition, the grinding wheel of the centerless grinder is generally quite wide, so that the time for dressing the grinding wheel is quite long each time, and the feeding of the grinding wheel is stopped each time the grinding wheel is dressed, thereby seriously affecting the grinding efficiency; the traditional numerical control centerless grinding machine cannot carry out grinding wheel dressing and workpiece grinding simultaneously, and workpiece grinding must be stopped when the grinding wheel is dressed, so that the production efficiency is seriously affected.
Disclosure of Invention
The invention aims to provide a centerless grinder compensation control system and method based on numerical control analysis, so as to solve the problems in the background technology.
In order to solve the technical problems, the invention provides the following technical scheme: the centerless grinder compensation control system based on numerical control analysis comprises a workpiece size measurement module, a workpiece size dispersion analysis and feedback module, an edge trimming grinding wheel trimming execution module and an edge trimming grinding size compensation feeding module;
the workpiece size measurement module is used for measuring the size of a workpiece at the discharging position of the centerless grinder, judging the tolerance range of the size of the measured workpiece according to the measurement result, and transmitting the judgment result to the workpiece size dispersion analysis and feedback module;
the workpiece size dispersion analysis and feedback module is used for continuously collecting the judging result of the workpiece, analyzing and evaluating the size dispersion of the workpiece in the evaluation period according to the collected data, judging the defect condition of the real-time grinding wheel, and feeding the evaluating result back to the edge trimming grinding size compensation feeding module and the edge trimming grinding wheel trimming executing module;
the edge trimming grinding wheel trimming execution module is used for starting the edge trimming grinding wheel trimming execution module to perform online trimming on the grinding wheel when the defect of the grinding wheel is aggravated in the grinding process of the workpiece; the edge trimming grinding wheel trimming execution module is also used for transmitting trimming state data related to size compensation to the edge trimming grinding size compensation feeding module;
the edge trimming grinding size compensation feeding module is used for starting the edge trimming grinding wheel trimming execution module and simultaneously starting the edge trimming grinding wheel trimming execution module, and carrying out size compensation of the edge trimming grinding on the workpiece being ground according to trimming state data related to real-time size compensation and analysis and evaluation results of workpiece size dispersion. The size compensation is to control the size of the workpiece within the range of precision requirement, and finally, edge trimming and grinding are realized.
Further, the workpiece size measurement module comprises a laser measurement head unit, a laser measurement controller unit and a PLC unit of the numerical control system;
the laser measuring head in the laser measuring head unit is arranged at the tail end of the discharging frame at the discharging position of the centerless grinder, the laser measuring head unit is connected with the laser measuring controller unit, and the laser measuring controller unit is connected with the PLC unit of the numerical control system;
the PLC unit of the numerical control system controls the laser measurement controller to work, the laser measurement head scans each workpiece passing through the laser scanning area, and measured data are transmitted to the laser measurement controller;
the laser measurement controller unit analyzes the measured data, judges the tolerance range of the size of the measured workpiece, and transmits the judging result to the input end of the workpiece size dispersion analysis and feedback module.
Further, the laser measurement controller unit analyzes the measured data to determine a tolerance range of the size of the measured workpiece, and the method comprises the following steps:
the laser measurement controller is connected with the signal line, the signal line transmits 8bit state indication signals, different 8bit state indication signals correspond to different measuring instrument states and judging results, corresponding symbol marks exist in the measuring instrument states and the judging results, the laser measurement controller unit transmits the state indication signals to the workpiece size dispersion analysis and feedback module, and the workpiece size dispersion analysis and feedback module displays the corresponding symbol marks;
the 8bit status indication signals include 10000000, 01000000, 0100000, 01010000, 01001000, 01000100, 01000010, and 01000001;
the measuring instrument state and the judging result comprise measuring instrument faults, the automatic mode of the measuring instrument is effective, the middle and lower limit early warning, the upper limit early warning, the lower tolerance, the upper tolerance and the nominal range of the measuring instrument;
the symbol identifiers include-AL, +AL, -OK, +OK and OK.
Further, the analysis and evaluation of size dispersion are carried out on the workpiece in the evaluation period, and the real-time grinding wheel defect condition is judged, and the method comprises the following steps:
the workpiece size dispersion analysis and feedback module stores the state indication signals acquired by the input end to acquire accumulated numbers D11 of first symbol marks and accumulated numbers D12 of second symbol marks, wherein the accumulated numbers D11 and D12 of the first symbol marks continuously appear in the corresponding signals in the evaluation period, and the corresponding signals can reflect signals related to abrasion of the grinding wheel in the operation monitoring process; the corresponding signals include 01000001 and 01000010; the first symbol is marked as OK, and the second symbol is marked as +OK;
calculating a first ratio D21, d21=d12/D11 within the evaluation period;
setting a minimum workpiece number threshold value n1 of a second symbol mark continuously occurring when slight particle falling abrasion exists, a minimum workpiece number threshold value n2 of the second symbol mark when the particle falling of the grinding wheel is aggravated, and a maximum ratio threshold value n11 of the second symbol mark to the first symbol mark according to historical data;
judging whether the following first conditions are satisfied in the evaluation period: n1.ltoreq.D12.ltoreq.n2 or n0.ltoreq.D21.ltoreq.n11;
if any first condition is met, outputting that the grinding wheel has slight particle falling abrasion, wherein the trimming grinding wheel trimming execution module for trimming the edge does not respond, and the workpiece size dispersion analysis and feedback module transmits a signal to the trimming grinding size compensation feeding module for trimming the edge, wherein n0 is the minimum percentage of accumulated numbers of preset second symbol marks and first symbol marks;
judging whether the following second condition is satisfied in the evaluation period: d1 > n2 or D21 > n11;
if any second condition is met, the grinding wheel particle falling is increased, a signal is transmitted to the edge trimming grinding wheel trimming execution module, if the maximum ratio threshold value n11 is the ratio of the second symbol mark to the first symbol mark when the grinding wheel abrasion begins to be increased, and when the first ratio D21 is larger than n11, the grinding wheel abrasion is considered to be increased.
Further, the setting of the evaluation period includes the steps of:
when D12 is more than or equal to 1, starting to count signals corresponding to the first symbol mark until signals corresponding to the next second symbol mark appear, and setting the process as an evaluation period N1;
in the evaluation period N1, the ratio of D12/D11 is calculated and stored in D21, D21 is updated, D11 and D12 are cleared, and the next evaluation period is started.
Further, the edge trimming grinding wheel trimming execution module comprises a fountain pen unit, a grinding wheel trimming feeding shaft unit and a grinding wheel trimming reciprocating shaft unit;
the fountain pen unit is used for subdividing a grinding area of the grinding wheel along a dressing reciprocating shaft controlled by the grinding wheel dressing reciprocating shaft unit and then dressing the grinding area in sections; the grinding wheel dressing feed shaft unit is used for providing a feed direction for the fountain pen controlled by the fountain pen unit; the grinding wheel dressing reciprocating shaft unit is used for providing feeding carrier for the fountain pen controlled by the fountain pen unit;
the trimming amount and the trimming speed of each section are respectively set by the trimming and grinding wheel trimming execution module, an trimming and grinding parameter setting interface is established by writing an HMI program, and the interface provides an operator to input parameters related to grinding wheel trimming into the NCK of the numerical control system; the dynamic change of the parameters related to grinding wheel dressing in the running process is dressing state data related to size compensation;
the parameters related to the grinding wheel dressing include the feeding amount U1 of the fountain pen in the U1 direction, coordinates (a 0, b 0) to (an, bn) in a coordinate system corresponding to the segment dressing, and dressing speeds f0 to fn of the segment dressing on the W1 axis;
the feeding amount U1 is the same as the dressing amount, the direction of U1 refers to the direction of a dressing feeding axis U1 controlled by a dressing feeding axis unit, and the axis W1 refers to a dressing reciprocating axis W1 controlled by a dressing reciprocating axis unit; the coordinate system corresponding to the sectional dressing is a coordinate system formed by taking a grinding wheel dressing feed shaft U1 as a transverse axis and a grinding wheel dressing reciprocating shaft W1 as a longitudinal axis;
the trimming execution module of the edge trimming grinding wheel is provided with a third condition that the trimming quantity is required to meet the third condition that the upper tolerance value is not more than the trimming quantity u1 and not more than the upper tolerance value plus 0.005mm; upper tolerance value = upper acceptance limit of work-work basic size;
and when the trimming execution module of the edge trimming grinding wheel works, a signal is transmitted to the edge trimming grinding size compensation feeding module. While trimming the grinding wheel on line, the diameter of the grinding wheel can change section by section in the W1 axis direction, and the size of the ground workpiece can also change along with the advancement of the trimming process. In order to keep the size of the workpiece to be ground within the tolerance range, the grinding wheel is dressed while the edge trimming grinding size compensation feeding module is required to be started.
Further, the edge trimming and grinding size compensation feeding module comprises a size compensation feeding shaft unit and a real-time data acquisition unit;
the real-time data acquisition unit is used for acquiring coordinate values of a W1 axis and trimming speed in trimming state data related to size compensation fed back in real time, and the real-time data acquisition unit is used for judging the current process of trimming the grinding wheel; the real-time data acquisition unit transmits the process result to the size compensation feeding shaft unit;
the size compensation feeding shaft unit is used for setting the number of workpieces at a first distance and trimming the size compensation amount during feeding compensation; the first distance is the position distance between the workpiece outlet and the workpiece measuring point; the size compensation feed shaft unit is provided with a size compensation feed shaft X1 axis.
The first distance causes a feedback lag of the workpiece size dispersion analysis and feedback module, thereby causing a lag in edge trimming size compensation, so the size compensation feed shaft unit is provided to reduce errors.
Further, the size compensation feeding shaft unit obtains the segmentation condition in the edge trimming grinding wheel trimming execution module, and the compensation components X0-xn of each segment of X1 shaft are preset based on the segmentation condition, wherein the sum of the compensation components is smaller than or equal to the trimming quantity u1 of each time; the size compensation feeding shaft unit is used for determining a segment number to which the real-time grinding wheel dressing belongs based on the coordinate of the W1 shaft acquired by the real-time data acquisition unit and comparing the coordinate with a W1 coordinate value of a preset grinding wheel dressing segment point, and controlling the X1 shaft to feed and compensate according to a compensation component of the corresponding segment number according to the segment number;
the size compensation feeding shaft unit judges the size relation between the trimming amount u1 and a preset trimming amount threshold u 0;
when u1 is less than or equal to u0, the size compensation feed shaft unit reduces the compensation component and transmits a signal to NCK of the numerical control system, and the numerical control system adjusts the minimum resolution of X1 axis in the size compensation feed shaft. The X1 axis after resolution improvement well meets the requirement of X1 axis micro-movement piecewise size compensation.
Further, the edge trimming and grinding size compensation system also comprises an operation adjustment module;
the operation adjustment module is used for storing and recording the trimming state data and the size compensation data in each operation period, and the operation adjustment module constructs a grinding wheel trimming parameter set corresponding to the trimming state data into a first set and a size compensation parameter set corresponding to the size compensation data into a second set;
the operation adjustment module analyzes and acquires the similarity of the trimming state data and the trimming state data in the first set in real time to be a first similarity according to the first set and the second set in the historical data, and when the first similarity is larger than a first similarity threshold value, the grinding wheel trimming parameters in the first set are transmitted to control; and analyzing and acquiring the similarity of the size compensation data and the size compensation data in the second set in real time to obtain second similarity, and transmitting the size compensation parameters in the second set to control when the second similarity is larger than a second similarity threshold value. The operation adjustment module can enable the edge trimming and grinding size compensation system to tend to be stable, and improves the working efficiency of the system.
The centerless grinder compensation control method based on numerical control analysis comprises the following specific steps:
step S1: judging the tolerance range of the size of the workpiece to be measured by measuring the size of the workpiece;
step S2: judging the defect condition of the current grinding wheel based on the tolerance range;
step S3: and controlling the cooperative operation of size compensation and grinding wheel finishing in the centerless grinding machine based on the defect condition of the existing grinding wheel, and ensuring that the size precision of a workpiece at the discharging position of the centerless grinding machine meets the precision requirement.
Compared with the prior art, the invention has the following beneficial effects: the invention is based on the edge trimming grinding size compensation system and method of the numerical control centerless grinder, increases the detection and judgment of the state of 'the granule falling aggravation of the grinding wheel', and segments and trims the grinding area of the grinding wheel after subdivision while the grinding of the workpiece is continuous, and simultaneously compensates the feeding shaft to carry out segment size compensation along with the trimming process of the grinding wheel while trimming grinding, wherein each segment of compensation quantity can be set; besides, the grinding wheel can be dressed while the workpiece is ground, the size of the workpiece is controlled within the range of the precision requirement through a special size compensation system, the edge trimming and grinding is realized, the grinding efficiency of the centerless grinding machine can be greatly improved, and extra benefits are brought to users.
Drawings
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate the invention and together with the embodiments of the invention, serve to explain the invention. In the drawings:
FIG. 1 is a block diagram of a compensation control system of a centerless grinder based on numerical control analysis;
FIG. 2 is a block diagram of the operation of the centerless grinder compensation control system based on numerical control analysis of the present invention;
FIG. 3 is a functional block diagram of a numerical control system of the centerless grinder compensation control system based on numerical control analysis of the present invention;
FIG. 4 is a block diagram of a secondary development program of the centerless grinder compensation control system based on numerical control analysis according to the present invention;
FIG. 5 is a tolerance range map of the centerless grinder compensation control system based on numerical control analysis of the present invention;
FIG. 6 is a mechanical pattern of the wheel dressing of the centerless grinder compensation control system based on numerical control analysis of the present invention;
FIG. 7 is a schematic view of the centerless grinding machine compensation control system based on numerical control analysis of the present invention.
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. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1 to 7, the present invention provides the following technical solutions: the centerless grinder compensation control system based on numerical control analysis comprises a workpiece size measurement module, a workpiece size dispersion analysis and feedback module, an edge trimming grinding wheel trimming execution module and an edge trimming grinding size compensation feeding module;
the workpiece size measurement module is used for measuring the size of a workpiece at the discharging position of the centerless grinder, judging the tolerance range of the size of the measured workpiece according to the measurement result, and transmitting the judgment result to the workpiece size dispersion analysis and feedback module;
the workpiece size dispersion analysis and feedback module is used for continuously collecting the judging result of the workpiece, analyzing and evaluating the size dispersion of the workpiece in the evaluation period according to the collected data, judging the defect condition of the real-time grinding wheel, and feeding the evaluating result back to the edge trimming grinding size compensation feeding module and the edge trimming grinding wheel trimming executing module;
the edge trimming grinding wheel trimming execution module is used for starting the edge trimming grinding wheel trimming execution module to perform online trimming on the grinding wheel when the defect of the grinding wheel is aggravated in the grinding process of the workpiece; the edge trimming grinding wheel trimming execution module is also used for transmitting trimming state data related to size compensation to the edge trimming grinding size compensation feeding module;
the edge trimming grinding size compensation feeding module is used for starting the edge trimming grinding wheel trimming execution module and simultaneously starting the edge trimming grinding wheel trimming execution module, and carrying out size compensation of the edge trimming grinding on the workpiece being ground according to trimming state data related to real-time size compensation and analysis and evaluation results of workpiece size dispersion. The size compensation is to control the size of the workpiece within the range of precision requirement, and finally, edge trimming and grinding are realized.
The workpiece size measurement module comprises a laser measurement head unit, a laser measurement controller unit and a PLC unit of a numerical control system;
the laser measuring head in the laser measuring head unit is arranged at the tail end of the discharging frame at the discharging position of the centerless grinder, the laser measuring head unit is connected with the laser measuring controller unit, and the laser measuring controller unit is connected with the PLC unit of the numerical control system;
the PLC unit of the numerical control system controls the laser measurement controller to work, the laser measurement head scans each workpiece passing through the laser scanning area, and measured data are transmitted to the laser measurement controller;
the laser measurement controller unit analyzes the measured data, judges the tolerance range of the size of the measured workpiece, and transmits the judging result to the input end of the workpiece size dispersion analysis and feedback module.
The laser measurement controller unit analyzes the measured data and judges the tolerance range of the size of the measured workpiece, and the method comprises the following steps:
the laser measurement controller is connected with the signal line, the signal line transmits 8bit state indication signals, different 8bit state indication signals correspond to different measuring instrument states and judging results, corresponding symbol marks exist in the measuring instrument states and the judging results, the laser measurement controller unit transmits the state indication signals to the workpiece size dispersion analysis and feedback module, and the workpiece size dispersion analysis and feedback module displays the corresponding symbol marks;
the 8bit status indication signals include 10000000, 01000000, 0100000, 01010000, 01001000, 01000100, 01000010, and 01000001;
the measuring instrument state and the judging result comprise measuring instrument faults, the automatic mode of the measuring instrument is effective, the middle and lower limit early warning, the upper limit early warning, the lower tolerance, the upper tolerance and the nominal range of the measuring instrument;
the symbol identifiers include-AL, +AL, -OK, +OK and OK.
The correspondence between the 8bit state indication signal and the state of the measuring instrument and the judgment result and symbol identification are shown in fig. 5.
Analyzing and evaluating size dispersion of the workpiece in the evaluation period, and judging the defect condition of the real-time grinding wheel, wherein the method comprises the following steps of:
the workpiece size dispersion analysis and feedback module stores the state indication signals acquired by the input end to acquire accumulated numbers D11 of first symbol marks and accumulated numbers D12 of second symbol marks, wherein the accumulated numbers D11 and D12 of the first symbol marks continuously appear in the corresponding signals in the evaluation period, and the corresponding signals can reflect signals related to abrasion of the grinding wheel in the operation monitoring process; the corresponding signals include 01000001 and 01000010; the first symbol is marked as OK, and the second symbol is marked as +OK; the state and the judging result of the measuring instrument corresponding to the first coincidence mark OK are in a nominal range, and the state and the judging result of the measuring instrument corresponding to the second symbol mark +OK are in an upper tolerance;
calculating a first ratio D21, d21=d12/D11 within the evaluation period;
setting a minimum workpiece number threshold value n1 of a second symbol mark continuously occurring when slight particle falling abrasion exists, a minimum workpiece number threshold value n2 of the second symbol mark when the particle falling of the grinding wheel is aggravated, and a maximum ratio threshold value n11 of the second symbol mark to the first symbol mark according to historical data;
the threshold values are all values which are set when the grinding wheel slightly drops grains and the grinding wheel drops grains are aggravated through historical grinding data and grinding experience;
judging whether the following first conditions are satisfied in the evaluation period: n1.ltoreq.D12.ltoreq.n2 or n0.ltoreq.D21.ltoreq.n11;
if any first condition is met, outputting that the grinding wheel has slight particle falling abrasion, wherein the trimming grinding wheel trimming execution module for trimming the edge does not respond, and the workpiece size dispersion analysis and feedback module transmits a signal to the trimming grinding size compensation feeding module for trimming the edge, wherein n0 is the minimum percentage of accumulated numbers of preset second symbol marks and first symbol marks; let n0=20% in general;
judging whether the following second condition is satisfied in the evaluation period: d12 > n2 or D21 > n11;
if any second condition is met, outputting the grinding wheel to increase the particle dropping, and transmitting a signal to the trimming and grinding wheel trimming execution module. At this time, it is determined from the data that the dimension confirmation has deviated from the nominal region of the workpiece dimension, and the dimension compensation is required to be performed simultaneously when the online dressing of the grinding wheel is performed. If the maximum ratio threshold n11 is the ratio of the second symbol mark to the first symbol mark when the abrasion of the grinding wheel begins to be increased, the abrasion of the grinding wheel is considered to be increased when the first ratio D21 is larger than n 11.
The setting of the evaluation period includes the steps of:
when D12 is more than or equal to 1, starting to count signals corresponding to the first symbol mark until signals corresponding to the next second symbol mark appear, and setting the process as an evaluation period N1;
in the evaluation period N1, the ratio of D12/D11 is calculated and stored in D21, D21 is updated, D11 and D12 are cleared, and the next evaluation period is started.
The edge trimming grinding wheel trimming execution module comprises a fountain pen unit, a grinding wheel trimming feed shaft unit and a grinding wheel trimming reciprocating shaft unit;
the fountain pen unit is used for subdividing a grinding area of the grinding wheel along a dressing reciprocating shaft controlled by the grinding wheel dressing reciprocating shaft unit and then dressing the grinding area in sections; the grinding wheel dressing feed shaft unit is used for providing a feed direction for the fountain pen controlled by the fountain pen unit; the grinding wheel dressing reciprocating shaft unit is used for providing feeding carrier for the fountain pen controlled by the fountain pen unit;
the trimming amount and the trimming speed of each section are respectively set by the trimming and grinding wheel trimming execution module, an trimming and grinding parameter setting interface is established by writing an HMI program, and the interface provides an operator to input parameters related to grinding wheel trimming into the NCK of the numerical control system; the dynamic change of the parameters related to grinding wheel dressing in the running process is dressing state data related to size compensation;
the parameters related to the grinding wheel dressing include the feeding amount U1 of the fountain pen in the U1 direction, coordinates (a 0, b 0) to (an, bn) in a coordinate system corresponding to the segment dressing, and dressing speeds f0 to fn of the segment dressing on the W1 axis;
the feeding amount U1 is the same as the dressing amount, the direction of U1 refers to the direction of a dressing feeding axis U1 controlled by a dressing feeding axis unit, and the axis W1 refers to a dressing reciprocating axis W1 controlled by a dressing reciprocating axis unit; the coordinate system corresponding to the sectional dressing is a coordinate system formed by taking a grinding wheel dressing feed shaft U1 as a transverse axis and a grinding wheel dressing reciprocating shaft W1 as a longitudinal axis;
the trimming execution module of the edge trimming grinding wheel is provided with a third condition that the trimming quantity is required to meet the third condition that the upper tolerance value is not more than the trimming quantity u1 and not more than the upper tolerance value plus 0.005mm; upper tolerance value = upper acceptance limit of work-work basic size; as shown in the examples: basic dimensions of the workpiece: 20.000, acceptance limit on work piece: 20.005, upper tolerance value = 20.005-20.000 = 0.005;
and when the trimming execution module of the edge trimming grinding wheel works, a signal is transmitted to the edge trimming grinding size compensation feeding module. While trimming the grinding wheel on line, the diameter of the grinding wheel can change section by section in the W1 axis direction, and the size of the ground workpiece can also change along with the advancement of the trimming process. In order to keep the size of the workpiece to be ground within the tolerance range, the grinding wheel is dressed while the edge trimming grinding size compensation feeding module is required to be started.
The mechanical structure diagram of the grinding wheel dressing of the centerless grinder is shown in fig. 6;
the number of segments after the grinding area of the grinding wheel is subdivided and the length of each segment are empirical values, and can be set according to the material of the grinding wheel, the type of the workpiece and the grinding amount used in actual grinding. When a workpiece is roughly ground, the grinding quantity is large at one time, the used grinding wheel is soft in material and small in grain number, the grain dropping speed of the grinding wheel is high, and when the grinding wheel is dressed, a plurality of sections are needed, and n=8-10 is generally set; when the workpiece is semi-finished, the grinding quantity is smaller at one time, the used grinding wheel is hard in material and has a large number of grains, the grain dropping speed of the grinding wheel is low, the size change range of the workpiece is small, the change speed is low, the number of segments can be smaller when the grinding wheel is finished, and n=6-8 is generally set. The trimming process of the edge trimming mill is completed by NCK of a numerical control system, and an NCK program is written according to the process requirement of the sectional trimming during the edge trimming mill.
The edge trimming and grinding size compensation feeding module comprises a size compensation feeding shaft unit and a real-time data acquisition unit;
the real-time data acquisition unit is used for acquiring coordinate values of a W1 axis and trimming speed in trimming state data related to size compensation fed back in real time, and the real-time data acquisition unit is used for judging the current process of trimming the grinding wheel; the real-time data acquisition unit transmits the process result to the size compensation feeding shaft unit;
the size compensation feeding shaft unit is used for setting the number of workpieces at a first distance and trimming the size compensation amount during feeding compensation; the first distance is the position distance between the workpiece outlet and the workpiece measuring point; the size compensation feed shaft unit is provided with a size compensation feed shaft X1 axis.
The first distance causes the dispersion analysis of the workpiece size and the feedback lag of the feedback module, thereby causing the size compensation lag of the edge trimming and grinding, so that the size compensation feed shaft unit is arranged to reduce errors; the size compensation feeding shaft adopts servo control, and the size compensation feeding shaft is a grinding frame feeding shaft; the grinding schematic diagram of the centerless grinder is shown in fig. 7; when the edge trimming and grinding is performed, the grinding wheel is used for trimming in sections, the workpiece continuously passes through a grinding area between the grinding wheel and the guide wheel, the X1 axial direction moves slightly in the positive direction, the width of the workpiece grinding area between the grinding wheel and the guide wheel is reduced, and the purpose of performing size compensation on the workpiece being ground is achieved.
The size compensation feeding shaft unit obtains the segmentation condition in the edge trimming grinding wheel trimming execution module, and the compensation components X0-xn of each segment of X1 shaft are preset based on the segmentation condition, wherein the sum of the compensation components is smaller than or equal to the trimming quantity u1 of each time; the size compensation feeding shaft unit is used for determining a segment number to which the real-time grinding wheel dressing belongs based on the coordinate of the W1 shaft acquired by the real-time data acquisition unit and comparing the coordinate with a W1 coordinate value of a preset grinding wheel dressing segment point, and controlling the X1 shaft to feed and compensate according to a compensation component of the corresponding segment number according to the segment number;
the size compensation feeding shaft unit judges the size relation between the trimming amount u1 and a preset trimming amount threshold u0, wherein the preset trimming amount threshold u0=0.005;
when u1 is less than or equal to u0, the size compensation feed shaft unit reduces the compensation component and transmits a signal to NCK of the numerical control system, and the numerical control system adjusts the minimum resolution of X1 axis in the size compensation feed shaft. Here, the minimum resolution of the X1 axis is increased from 1um to 0.1um by adjusting the NCK axis parameter in the digital control system. The X1 axis after resolution improvement well meets the requirement of X1 axis micro-movement piecewise size compensation.
The edge trimming and grinding size compensation system also comprises an operation adjustment module;
the operation adjustment module is used for storing and recording the trimming state data and the size compensation data in each operation period, and the operation adjustment module constructs a grinding wheel trimming parameter set corresponding to the trimming state data into a first set and a size compensation parameter set corresponding to the size compensation data into a second set;
the operation adjustment module analyzes and acquires the similarity of the trimming state data and the trimming state data in the first set in real time to be a first similarity according to the first set and the second set in the historical data, and when the first similarity is larger than a first similarity threshold value, the grinding wheel trimming parameters in the first set are transmitted to control; and analyzing and acquiring the similarity of the size compensation data and the size compensation data in the second set in real time to obtain second similarity, and transmitting the size compensation parameters in the second set to control when the second similarity is larger than a second similarity threshold value. The operation adjustment module can enable the edge trimming and grinding size compensation system to tend to be stable, and improves the working efficiency of the system.
The edge trimming and grinding size compensation system of the numerical control centerless grinder firstly judges the tolerance range of the size of a workpiece to be measured through a workpiece size measurement module, then judges the current defect condition of the grinding wheel through a workpiece size dispersion analysis and feedback module, and then cooperatively operates with an edge trimming and grinding size compensation feeding module through an edge trimming grinding wheel trimming execution module, so that the workpiece size precision at the discharging position of the centerless grinder is ensured to meet the precision requirement, and the purpose of edge trimming and grinding is achieved;
the edge trimming and grinding size compensation system is established based on a control system of a machine tool, the control system of the centerless grinding machine is controlled by a numerical control system, and the edge trimming and grinding size compensation system of the numerical control centerless grinding machine is constructed by carrying out secondary development on the numerical control system. The numerical control system functional block diagram is shown in fig. 3;
all parameter setting and state monitoring related to the edge trimming and grinding size compensation system are completed through an HMI in the figure; the workpiece size measuring module and the workpiece size dispersion analysis and feedback module in the edge trimming and grinding size compensation system are all completed by a PLC in the figure; the 'side trimming grinding wheel trimming execution module' and the 'side trimming grinding size compensation feeding module' in the side trimming grinding size compensation system are completed by NCK in the figure; and a control block diagram 4 of a numerical control centerless grinding machine edge trimming grinding size compensation system.
The centerless grinder compensation control method based on numerical control analysis comprises the following specific steps:
step S1: judging the tolerance range of the size of the workpiece to be measured by measuring the size of the workpiece;
step S2: judging the defect condition of the current grinding wheel based on the tolerance range;
step S3: and controlling the cooperative operation of size compensation and grinding wheel finishing in the centerless grinding machine based on the defect condition of the existing grinding wheel, and ensuring that the size precision of a workpiece at the discharging position of the centerless grinding machine meets the precision requirement.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be noted that: the foregoing description is only a preferred embodiment of the present invention, and the present invention is not limited thereto, but it is to be understood that modifications and equivalents of some of the technical features described in the foregoing embodiments may be made by those skilled in the art, although the present invention has been described in detail with reference to the foregoing embodiments. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims (8)

1. The centerless grinder compensation control system based on numerical control analysis is characterized by comprising a workpiece size measurement module, a workpiece size dispersion analysis and feedback module, an edge trimming grinding wheel trimming execution module and an edge trimming grinding size compensation feeding module;
the workpiece size measurement module is used for measuring the size of a workpiece at the discharging position of the centerless grinder, judging the tolerance range of the size of the measured workpiece according to the measurement result, and transmitting the judgment result to the workpiece size dispersion analysis and feedback module;
the workpiece size measurement module comprises a laser measurement head unit, a laser measurement controller unit and a PLC unit of a numerical control system;
the laser measuring head in the laser measuring head unit is arranged at the tail end of the discharging frame at the discharging position of the centerless grinder, the laser measuring head unit is connected with the laser measuring controller unit, and the laser measuring controller unit is connected with the PLC unit of the numerical control system;
the PLC unit of the numerical control system controls the laser measurement controller to work, the laser measurement head scans each workpiece passing through the laser scanning area, and measured data are transmitted to the laser measurement controller;
the laser measurement controller unit analyzes the measured data, judges the tolerance range of the size of the measured workpiece, and transmits the judging result to the input end of the workpiece size dispersion analysis and feedback module;
the laser measurement controller unit analyzes the measured data and judges the tolerance range of the size of the measured workpiece, and the method comprises the following steps:
the laser measurement controller is connected with the signal line, the signal line transmits 8bit state indication signals, different 8bit state indication signals correspond to different measuring instrument states and judging results, corresponding symbol marks exist on the measuring instrument states and judging results, the laser measurement controller unit transmits the state indication signals to the workpiece size dispersion analysis and feedback module, and the workpiece size dispersion analysis and feedback module displays the corresponding symbol marks;
the 8bit status indication signal includes 10000000, 01000000, 0100000, 01010000, 01001000, 01000100, 01000010 and 01000001;
the measuring instrument state and the judging result comprise measuring instrument faults, measuring instrument automatic mode validation, measuring middle and lower limit early warning, upper limit early warning, lower tolerance, upper tolerance and nominal range;
the symbol identifiers comprise-AL, +AL, -OK, +OK and OK;
the workpiece size dispersion analysis and feedback module is used for continuously collecting the judging result of the workpiece, analyzing and evaluating the size dispersion of the workpiece in the evaluation period according to the collected data, judging the defect condition of the real-time grinding wheel, and feeding the evaluating result back to the edge trimming grinding size compensation feeding module and the edge trimming grinding wheel trimming executing module;
the edge trimming grinding wheel dressing execution module is used for starting the edge trimming grinding wheel dressing execution module to carry out online dressing on the grinding wheel when the defect of the grinding wheel is aggravated in the grinding process of the workpiece; the edge trimming grinding wheel trimming execution module is also used for transmitting trimming state data related to size compensation to the edge trimming grinding size compensation feeding module;
the edge trimming grinding size compensation feeding module is used for starting the edge trimming grinding wheel trimming executing module at the same time, and performing size compensation of the edge trimming grinding on the workpiece being ground according to trimming state data related to real-time size compensation and analysis and evaluation results of workpiece size dispersion.
2. The numerically controlled analysis-based centerless grinder compensation control system according to claim 1, wherein: the analysis and evaluation of size dispersion are carried out on the workpiece in the evaluation period, and the real-time grinding wheel defect condition is judged, and the method comprises the following steps:
the workpiece size dispersion analysis and feedback module stores the state indication signals acquired by the input end to acquire accumulated numbers D11 of first symbol marks and accumulated numbers D12 of second symbol marks, wherein the accumulated numbers D11 and D12 of the first symbol marks continuously appear in an evaluation period, and the corresponding signals can reflect signals related to abrasion of the grinding wheel in the operation monitoring process; the corresponding signals include 01000001 and 01000010; the first symbol is marked as OK, and the second symbol is marked as +OK;
calculating a first ratio D21, d21=d12/D11 within the evaluation period;
setting a minimum workpiece number threshold value n1 of a second symbol mark continuously occurring when slight particle falling abrasion exists, a minimum workpiece number threshold value n2 of the second symbol mark when the particle falling of the grinding wheel is aggravated, and a maximum ratio threshold value n11 of the second symbol mark to the first symbol mark according to historical data;
judging whether the following first conditions are satisfied in the evaluation period: n1.ltoreq.D12.ltoreq.n2 or n0.ltoreq.D21.ltoreq.n11;
if any first condition is met, the output grinding wheel has slight particle dropping abrasion, the edge trimming grinding wheel trimming execution module does not respond, the workpiece size dispersion analysis and feedback module transmits signals to the edge trimming grinding size compensation feeding module, and n0 is the minimum percentage of accumulated numbers of preset second symbol marks and first symbol marks;
judging whether the following second condition is satisfied in the evaluation period: d12 > n2 or D21 > n11;
if any second condition is met, outputting the aggravated falling grains of the grinding wheel, and transmitting a signal to the trimming execution module of the edge trimming grinding wheel.
3. The numerically controlled analysis-based centerless grinder compensation control system according to claim 2, wherein: the setting of the evaluation period includes the steps of:
when D12 is more than or equal to 1, starting to count signals corresponding to the first symbol mark until signals corresponding to the next second symbol mark appear, and setting the process as an evaluation period N1;
in the evaluation period N1, the ratio of D12/D11 is calculated and stored in D21, D21 is updated, D11 and D12 are cleared, and the next evaluation period is started.
4. A centerless grinder compensation control system based on numerical control analysis according to claim 3, wherein: the edge trimming grinding wheel trimming execution module comprises a fountain pen unit, a grinding wheel trimming feeding shaft unit and a grinding wheel trimming reciprocating shaft unit;
the fountain pen unit is used for subdividing a grinding area of the grinding wheel along a trimming reciprocating shaft controlled by the grinding wheel trimming reciprocating shaft unit and then trimming the grinding area in sections; the grinding wheel dressing feed shaft unit is used for providing a feed direction for the fountain pen controlled by the fountain pen unit; the grinding wheel dressing reciprocating shaft unit is used for providing feeding carrier for the fountain pen controlled by the fountain pen unit;
the trimming amount and the trimming speed of each section are respectively set by the trimming grinding wheel trimming execution module, an trimming grinding parameter setting interface is established by writing an HMI program, and the interface provides an operator to input parameters related to grinding wheel trimming into NCK of a numerical control system; the dynamic change of the parameters related to grinding wheel dressing in the running process is dressing state data related to size compensation;
the parameters related to grinding wheel dressing comprise the feeding amount U1 of the fountain pen in the U1 direction, coordinates (a 0, b 0) to (an, bn) in a coordinate system corresponding to segment dressing and dressing speeds f0 to fn of segment dressing on the W1 axis;
the feeding amount U1 is the same as the dressing amount, the direction of the U1 refers to the direction of a grinding wheel dressing feeding shaft U1 controlled by a grinding wheel dressing feeding shaft unit, and the shaft W1 refers to a grinding wheel dressing reciprocating shaft W1 controlled by a grinding wheel dressing reciprocating shaft unit; the coordinate system corresponding to the sectional dressing is a coordinate system formed by taking a grinding wheel dressing feed shaft U1 as a transverse axis and a grinding wheel dressing reciprocating shaft W1 as a longitudinal axis;
the trimming execution module of the edge trimming grinding wheel is provided with a third condition that the trimming quantity is required to meet, wherein the third condition is that the upper tolerance value is not more than the trimming quantity u1 and not more than the upper tolerance value plus 0.005mm; the upper tolerance value = upper acceptance limit of the workpiece-workpiece base size;
and when the trimming execution module of the edge trimming grinding wheel works, a signal is transmitted to the edge trimming grinding size compensation feeding module.
5. The numerically controlled analysis based centerless grinder compensation control system according to claim 4, wherein: the edge trimming and grinding size compensation feeding module comprises a size compensation feeding shaft unit and a real-time data acquisition unit;
the real-time data acquisition unit is used for acquiring coordinate values of a W1 axis and trimming speed in trimming state data related to size compensation fed back in real time, and the real-time data acquisition unit is used for judging the current progress of trimming of the grinding wheel; the real-time data acquisition unit transmits a process result to the size compensation feed shaft unit;
the size compensation feeding shaft unit is used for setting the number of workpieces at a first distance and trimming the size compensation amount during feeding compensation; the first distance is the position distance between the workpiece outlet and the workpiece measuring point; the size compensation feed shaft unit is provided with a size compensation feed shaft X1 axis.
6. The numerically controlled analysis based centerless grinder compensation control system according to claim 5, wherein: the size compensation feeding shaft unit obtains the segmentation condition in the edge trimming grinding wheel trimming execution module, and presets compensation components X0-xn of each segment of X1 shaft based on the segmentation condition, wherein the sum of the compensation components is smaller than or equal to trimming amount u1 of each time; the size compensation feeding shaft unit is used for determining a segment number to which real-time grinding wheel dressing belongs based on the coordinate of the W1 shaft acquired by the real-time data acquisition unit and comparing the coordinate with a W1 coordinate value of a preset grinding wheel dressing segmentation point, and controlling the X1 shaft to feed and compensate according to a compensation component of the corresponding segment number according to the segment number;
the size compensation feeding shaft unit judges the size relation between the trimming amount u1 and a preset trimming amount threshold u 0;
when u1 is less than or equal to u0, the size compensation feeding shaft unit reduces the compensation component and transmits a signal to NCK of a numerical control system, and the numerical control system adjusts the minimum resolution of the X1 axis in the size compensation feeding shaft.
7. The numerically controlled analysis based centerless grinder compensation control system according to claim 6, wherein: the edge trimming and grinding size compensation system further comprises an operation adjustment module;
the operation adjustment module is used for storing and recording trimming state data and size compensation data in each operation period, and the operation adjustment module constructs a grinding wheel trimming parameter set corresponding to the trimming state data into a first set and a size compensation parameter set corresponding to the size compensation data into a second set;
the operation adjustment module analyzes and acquires the similarity of the trimming state data and the trimming state data in the first set in real time to be a first similarity according to the first set and the second set in the historical data, and when the first similarity is larger than a first similarity threshold value, the grinding wheel trimming parameters in the first set are transmitted to control; and analyzing and acquiring the similarity of the size compensation data and the size compensation data in the second set in real time to obtain second similarity, and transmitting the size compensation parameters in the second set to control when the second similarity is larger than a second similarity threshold value.
8. A method for controlling the compensation of a centerless grinding machine based on numerical control analysis using the centerless grinding machine compensation control system based on numerical control analysis according to any one of claims 1 to 7, comprising the following steps:
step S1: judging the tolerance range of the size of the workpiece to be measured by measuring the size of the workpiece;
step S2: judging the defect condition of the current grinding wheel based on the tolerance range;
step S3: and controlling the cooperative operation of size compensation and grinding wheel finishing in the centerless grinding machine based on the defect condition of the existing grinding wheel, and ensuring that the size precision of a workpiece at the discharging position of the centerless grinding machine meets the precision requirement.
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