CN116502036B - Machine tool health degree calculation method - Google Patents
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Abstract
The invention discloses a method for calculating the health degree of a machine tool, which calculates the benefit generated in the ideal state in the whole life cycle of the machine tool by utilizing the benefit generated before the first overhaul of the machine tool and calculates and predicts the health degree of the machine tool at a certain moment in the future by combining the benefit easy to generate by the machine tool. According to the invention, the benefits which can be realized in the ideal state in the whole life cycle of the machine tool are calculated based on the benefits generated before the first overhaul of the machine tool, and the health degree of the machine tool at a certain moment is calculated based on the benefits, so that the calculation of the health degree of the machine tool has a certain scientific basis, and the interference of artificial factors on the calculation of the health degree is reduced.
Description
Technical Field
The invention relates to the technical field of machine tool health monitoring. In particular to a method for calculating the health degree of a machine tool.
Background
Machine tools are used as core assets of enterprises, and the output ratio of the machine tools has a critical influence on the benefits of the enterprises. How to determine the health degree of the machine tool at a certain moment in the future is beneficial to determining the yield ratio of the machine tool at the moment, so that enterprises can conveniently adjust or arrange the production of the enterprises according to the health degree of the machine tool, and the influence of the machine tool with lower health degree on the production of the enterprises is avoided.
The existing machine tool health degree prediction method basically stays on the aspects of machine tool fault management, preventive maintenance and the like, and does not relate the machine tool health degree to the benefits which can be created in the service life period.
Disclosure of Invention
Therefore, the technical problem to be solved by the invention is to provide a method for calculating the health degree of the machine tool, which calculates the benefits which can be realized in the ideal state in the whole life cycle of the machine tool by utilizing the benefits generated before the first overhaul of the machine tool, calculates the health degree of the machine tool at a certain moment based on the benefits, and is convenient for enterprises to carry out production scheduling according to the health degree condition of the machine tool, thereby improving the economic benefits of the enterprises.
In order to solve the technical problems, the invention provides the following technical scheme:
a machine tool health degree calculating method comprises the following steps:
s1) calculating the achievable benefit P in the ideal state in the whole life cycle of the machine tool Ideal for The method comprises the following specific stepsThe following are provided:
s1-1) statistics of benefits generated when n machine tools are overhauled for the first timeWherein->The benefit produced when the machine tool is overhauled for the first time is marked as +.>，/>=1,2,3…，n;
S1-2) statistics of machine tool maintenance factor delta and machine tool maintenance time in step S1-1)；
S1-3) the benefit generated when the machine tool is first serviced according to the statistics in step S1-1)And the machine tool maintenance time counted in step S1-2)>Calculating the average ideal benefit generated by each machine tool before the n machine tools are put into production again>The specific formula is as follows:
wherein ,is->Working time of the machine tool before first overhaul;
s1-4) repeating step S1-1) to S1-3) statistics of average ideal benefit of each machine tool before putting m and k machine tools back into production after first overhaul，k≥1.5m，m≥1.5n；
S1-5) according to the ideal benefits of k, n and m machine toolsCalculating the +.>：
wherein ,the service life of the machine tool is ideal;
the average value of the normal work of the machine tool and the first maintenance duration is obtained when the first maintenance of the machine tool is completed;
s2) counting the running time of the machine toolBenefits achieved in->；
S3) predicting the machine tool to be operatedBenefits P achievable during time to T T Specifically, the method can be calculated by the following formula:
；
s4) P calculated according to step S1) Ideal for And step S2) statistical resultStep S3) predicting to obtain P T And the ideal lifetime of a machine tool +.>Is>The machine tool health was calculated by:
wherein ,the health degree of the machine tool at the moment T;
is the benefit which can be realized in the ideal state from the time T to the end of the ideal life of the machine tool.
In the above machine tool health degree calculation method, in step S1-2), the machine tool maintenance factor δ includes a non-trouble maintenance factor δ 1 And maintenance factor delta due to reasons 2 Wherein, the maintenance due to the accident refers to the maintenance of the machine tool caused by the fault; when there are n machine toolsThe machine tool is overhauled due to reasons and is->If it is greater than or equal to 0.2n, the value is calculated by the formula +.>：
wherein ,and correcting the coefficient for the ideal state of the machine tool.
In the above method for calculating the health degree of machine tools, in the step S1-5), when more than 50% of k, n and m machine tools are overhauled due to faults, the machine tools are overhauledCorrecting, wherein the ideal service life of the machine tool after correction is +.>。
The machine tool health degree calculating method is provided in step S3)Before and adjacent to the moment->The normal working time of the machine tool at the moment is t norm When->Greater than t norm And is less than or equal to t norm Twice as much as above, then P is calculated by T ：
wherein ,is->Correction coefficients.
The method for calculating the health degree of the machine tool is as followsBefore and adjacent to the moment->When the machine tool maintenance at the moment is due to reasons, the machine tool is in the +.>Forward regulation is carried out, and the regulating amplitude is 8-13%.
In the above machine tool health degree calculation method, in step S3), when the yield of the product produced by the machine tool is reduced by more than 5%, the machine tool is used for the following stepsAdjusting, adjusting +.>The method comprises the following steps:
wherein ,is adjacent->Product yield ratio of two adjacent statistical time periods at moment, and setting statistical time period +.> and />Middle->Is positioned at-> and />Between, statistical period->The product yield of (2) is->Statistical period->The product yield of (2) is->，/>。
In the above machine tool health degree calculating method, in step S2), the benefits achieved by the machine tool between adjacent normal trouble-free service time points are countedAnd calculate +.>Variation of (1)/(B)>When the reduction amplitude exceeds 15%, the service life of the machine tool is idealAnd (5) adjusting.
The method for calculating the health degree of the machine tool is as followsThe descending amplitude exceeds 15 percent and after the machine tool is overhauled/>When the lift-back amplitude is not more than 10%, the ideal life of the machine tool is +.>And performing reduction adjustment.
The technical scheme of the invention has the following beneficial technical effects:
according to the invention, the benefits which can be realized in the ideal state in the whole life cycle of the machine tool are calculated based on the benefits generated before the first overhaul of the machine tool, and the health degree of the machine tool at a certain moment is calculated based on the benefits, so that the calculation of the health degree of the machine tool has a certain scientific basis, the interference of artificial factors on the calculation of the health degree is reduced, the prediction of the health degree of the machine tool by enterprises according to the production conditions of the enterprises is facilitated, the production of the enterprises is reasonably regulated according to the health degree of the machine tool, and the benefits of the enterprises are further improved.
Drawings
Fig. 1 is a schematic flow chart of a method for calculating the health degree of a machine tool.
Detailed Description
As shown in fig. 1, the method for calculating the health degree of the machine tool comprises the following steps:
s1) calculating the achievable benefit P in the ideal state in the whole life cycle of the machine tool Ideal for The method comprises the following specific steps:
s1-1) statistics of benefits generated when n machine tools are overhauled for the first timeWherein->The benefit produced when the machine tool is overhauled for the first time is marked as +.>，/>=1,2,3…，n;
S1-2) Counting the maintenance factor delta of the machine tool and the maintenance time of the machine tool in the step S1-1)；
S1-3) the benefit generated when the machine tool is first serviced according to the statistics in step S1-1)And the machine tool maintenance time counted in step S1-2)>Calculating the average ideal benefit generated by each machine tool before the n machine tools are put into production again>The specific formula is as follows:
wherein ,is->Working time of the machine tool before first overhaul;
s1-4) repeating the steps S1-1) to S1-3) to count the average ideal benefit of each machine tool before the m machine tools and the k machine tools are put into production again after the first overhaul，k≥1.5m，m≥1.5n；
S1-5) according to the ideal benefits of k, n and m machine toolsCalculating the +.>：
wherein ,the ideal service life of the machine tool can be provided by a machine tool provider, can be obtained by industry experience, can be preset by an enterprise according to the self-production condition, and mainly refers to the enterprise production load condition, and the ideal service life of a full-load machine tool is shorter;
the average value of the normal work of the machine tool and the first maintenance duration is obtained when the first maintenance of the machine tool is completed;
s2) counting the running time of the machine toolBenefits achieved in->；
S3) predicting the machine tool to be operatedBenefits P achievable during time to T T Specifically, the method can be calculated by the following formula:
；
s4) P calculated according to step S1) Ideal for And step S2) statistical resultStep S3) predicting to obtain P T And the ideal lifetime of a machine tool +.>Is>The machine tool health was calculated by:
wherein ,the health degree of the machine tool at the moment T;
is the benefit which can be realized in the ideal state from the time T to the end of the ideal life of the machine tool.
The machine tool needs to be overhauled for a period of time to avoid the occurrence of emergency conditions in the machine tool operation process, and the factors delta of machine tool shutdown overhauling can have various conditions, in the embodiment, the machine tool overhauling factors delta are divided into two types, namely non-fault overhauling factors delta 1 And maintenance factor delta due to reasons 2 Wherein delta is compared to non-troubleshooting factors 1 The shutdown maintenance is caused, and the maintenance factor delta is caused due to the reasons 2 The resulting stoppage and maintenance can reduce the benefit of the machine tool before the first maintenance, so that when the number of the machine tools which are maintained in the plurality of machine tools due to reasons reaches a certain value, the machine tools need to be checkedCalibration is performed to ensure that the sum is +.>Calculated P Ideal for Which corresponds to the actual situation. When there are ∈n machine tools>The machine tool is overhauled due to reasons and is->When the number is greater than or equal to 0.2n, the calculation is carried out by the following formula：
wherein ,and correcting the coefficient for the ideal state of the machine tool.
When more than 50% of k, n and m machine tools are overhauled due to faults, the machine tools are overhauledCorrecting, wherein the ideal service life of the machine tool after correction is +.>。
When calculating and predicting the health of a machine tool at a certain moment, the production arrangement condition of enterprises, such as machine tool maintenance regulation, i.e. how often the machine tool is operated for maintenance, should be consideredIn the time of machine health, ifThe time length between the moment and the current moment exceeds the working time length of the machine tool between two adjacent overhaul periods, and P is needed T And (3) adjusting the calculation of the health degree of the machine tool to improve the accuracy of the calculation of the health degree of the machine tool. Thus, in step S3), set at +.>Before and adjacent to the moment->The normal working time of the machine tool at the moment is t norm When->Greater than t norm And is less than or equal to t norm Twice as much as above, then P is calculated by T ：
wherein ,is->Correction coefficients.
In view of the fact that the yield of products and the production speed are reduced in the production process of the machine tool before the fault of parts or other reasons occurs, when the machine tool is at T Has already been provided with Before the moment and adjacent to T Has already been provided with When the machine tool is overhauled at moment due to reasons, the machine tool is overhauledForward adjustment is carried out, the adjustment range is 8-13%, and the specific adjustment range is set according to the self condition of the machine tool and the product condition.
Since there may be some variation in yield of the product processed by the machine tool with the use of the machine tool, once the variation is large, the benefit of the machine tool generated in a certain period of time in the future will be affected, so in step S3), when the yield of the product obtained by the machine tool is reduced by more than 5%, the process is repeatedAdjusting, adjusting +.>The method comprises the following steps:
wherein ,is adjacent->The product yield ratio of two adjacent statistical time periods at the moment is specifically that the statistical time period +.> and />Middle->Is positioned at-> and />Between, statistical period->The product yield of (2) is->Statistical period->The product yield of (2) is->，/>。
In the process of processing and producing by using a machine tool, counting the generation of each normal production period in timeBenefit and yield, and statistics of time consumption of each maintenance so as to confirm benefit change condition generated in unit time of machine tool in use, and further to judge whether to ideal service life of machine tool when calculating health degree of machine toolAdjustment is made, i.e. the statistical benefit achieved by the machine tool between adjacent points of normal trouble-free service time ∈>And calculate +.>Variation of (1)/(B)>When the decrease amplitude exceeds 15%, the ideal life of the machine tool is +.>Adjusting, in particular adjusted +.>Is that, wherein ,/>Is->Decrease the amplitude, when->The descending amplitude exceeds 50%, and enterprises can judge whether to continue using the machine tool or not by themselves. While->The descending amplitude exceeds 15% and is +.>When the amplitude of the lift-off does not exceed 10%,ideal life of machine tool>And performing reduction adjustment. If the machine tool is overhauled +.>The benefits achieved between adjacent normal non-trouble-shooting time points after machine tool maintenance are equivalent to those achieved between adjacent normal non-trouble-shooting time points without a great reduction, so that the ideal service life of the machine tool is not required>And performing reduction adjustment.
According to the invention, the benefits generated in the ideal state in the full life cycle of the machine tool are calculated based on the benefits generated before the first overhaul of the machine tool, so that enterprises have more scientific basis for evaluating the expected benefits generated by the machine tool, thereby realizing more accurate prediction of the health degree of the machine tool, and the benefits generated in the ideal state in the full life cycle of the machine tool are adjusted along with the use condition of the machine tool, thereby being more beneficial to predicting the health degree of the machine tool at a certain moment in the future.
When the method is used for predicting the health degree of the existing machine tool from the start of production, the accuracy rate is up to 97%, and the accuracy rate for predicting the health degree of the machine tool is gradually increased along with the increase of the number of the machine tools and the total use time of a single machine tool.
It is apparent that the above examples are given by way of illustration only and are not limiting of the embodiments. Other variations or modifications of the above teachings will be apparent to those of ordinary skill in the art. It is not necessary here nor is it exhaustive of all embodiments. While the obvious variations or modifications which are extended therefrom remain within the scope of the claims of this patent application.
Claims (7)
1. The machine tool health degree calculating method is characterized by comprising the following steps of:
s1) calculating the achievable benefit P in the ideal state in the whole life cycle of the machine tool Ideal for The method comprises the following specific steps:
s1-1) statistics of benefits generated when n machine tools are overhauled for the first timeWherein->The benefit produced when the machine tool is overhauled for the first time is marked as +.>，/>=1,2,3…，n;
S1-2) statistics of machine tool maintenance factor delta and machine tool maintenance time in step S1-1)The method comprises the steps of carrying out a first treatment on the surface of the Machine tool service factors delta include non-fault service factors delta 1 And maintenance factor delta due to reasons 2 The method comprises the steps of carrying out a first treatment on the surface of the When there are ∈n machine tools>The machine tool is overhauled due to reasons and is->If it is greater than or equal to 0.2n, the value is calculated by the formula +.>：
wherein ,correction coefficient for ideal state of machine tool
S1-3) the benefit generated when the machine tool is first serviced according to the statistics in step S1-1)And the machine tool maintenance time counted in step S1-2)>Calculating the average ideal benefit generated by each machine tool before the n machine tools are put into production again>The specific formula is as follows:
wherein ,is->Working time of the machine tool before first overhaul;
s1-4) repeating the steps S1-1) to S1-3) to count the average ideal benefit of each machine tool before the m machine tools and the k machine tools are put into production again after the first overhaul，k≥1.5m，m≥1.5n；
S1-5) according to the ideal benefits of k, n and m machine toolsCalculating the +.>：
wherein ,the service life of the machine tool is ideal;
the average value of the normal work of the machine tool and the first maintenance duration is obtained when the first maintenance of the machine tool is completed;
s2) counting the running time T of the machine tool Has already been provided with Benefits P achieved in Has already been provided with ；
S3) predicting the machine tool to be at the slave T Has already been provided with Benefits P achievable during time to T T Specifically, the method can be calculated by the following formula:
；
s4) P calculated according to step S1) Ideal for And step S2) counting the obtained P Has already been provided with Step S3) predicting to obtain P T Ideal life of machine toolWith the machine tool operated time T Has already been provided with The machine tool health was calculated by:
wherein ,the health degree of the machine tool at the moment T;
is the benefit which can be realized in the ideal state from the time T to the end of the ideal life of the machine tool.
2. The method for calculating the health degree of a machine tool according to claim 1, wherein in the step S1-5), when more than 50% of all the k, n and m machine tools are serviced due to failure, the machine tool is subjected to the following processCorrecting, wherein the ideal service life of the machine tool after correction is +.>。
3. The method for calculating the health degree of a machine tool according to claim 1, wherein in step S3), the calculation result is set at T Has already been provided with Before the moment and adjacent to T Has already been provided with The normal working time of the machine tool at the moment is t norm When (when)Greater than t norm And is less than or equal to t norm Twice as much as above, then P is calculated by T ：
wherein ,is->Correction coefficients.
4. A machine tool health calculation method according to claim 3, wherein when at T Has already been provided with Before the moment and adjacent to T Has already been provided with When the machine tool is overhauled at moment due to reasons, the machine tool is overhauledForward regulation is carried out, and the regulating amplitude is 8-13%.
5. A machine tool health degree calculation method according to claim 3, wherein in step S3), when the yield of the product obtained by machine tool production decreases by more than 5%, thenAdjusting, adjusting +.>The method comprises the following steps:
wherein ,is adjacent->Product yield ratio of two adjacent statistical time periods at moment, and setting statistical time period +.> and />Middle->Is positioned at-> and />Between, statistical period->The product yield of (2) is->Statistical period->The product yield of (2) is->,。
6. The method according to any one of claims 1 to 5, characterized in that in step S2), the benefit achieved by the machine between adjacent points in time of normal trouble-free service is countedAnd calculate +.>Variation of (1)/(B)>The descending amplitude exceeds 15% and is +.>When no lift-back occurs, the ideal life of the machine tool is +.>And performing reduction adjustment.
7. The method for calculating the health degree of a machine tool according to claim 6, wherein whenThe descending amplitude exceeds 15% and is +.>When the lift-back amplitude is not more than 10%, the ideal life of the machine tool is +.>And performing reduction adjustment.
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| CN114218868A (en) * | 2021-12-21 | 2022-03-22 | 北京安盟信息技术股份有限公司 | Machine tool health degree calculation method based on life cycle benefit prediction |
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| CN114218868A (en) * | 2021-12-21 | 2022-03-22 | 北京安盟信息技术股份有限公司 | Machine tool health degree calculation method based on life cycle benefit prediction |
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