CN116533062A - Cutter wear monitoring method based on power measurement - Google Patents
Cutter wear monitoring method based on power measurement Download PDFInfo
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- CN116533062A CN116533062A CN202310523963.9A CN202310523963A CN116533062A CN 116533062 A CN116533062 A CN 116533062A CN 202310523963 A CN202310523963 A CN 202310523963A CN 116533062 A CN116533062 A CN 116533062A
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- 238000000034 method Methods 0.000 title claims abstract description 42
- 238000012544 monitoring process Methods 0.000 title claims abstract description 17
- 238000005259 measurement Methods 0.000 title claims abstract description 13
- 238000012545 processing Methods 0.000 claims abstract description 75
- 238000004519 manufacturing process Methods 0.000 claims abstract description 10
- 230000003750 conditioning effect Effects 0.000 claims description 21
- 238000003754 machining Methods 0.000 claims description 18
- 230000002159 abnormal effect Effects 0.000 claims description 12
- 238000004891 communication Methods 0.000 claims description 3
- 238000003062 neural network model Methods 0.000 claims description 3
- 238000012360 testing method Methods 0.000 claims description 3
- 238000012549 training Methods 0.000 claims description 3
- 238000012423 maintenance Methods 0.000 abstract description 2
- 238000005299 abrasion Methods 0.000 description 5
- 230000002035 prolonged effect Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0957—Detection of tool breakage
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q11/00—Accessories fitted to machine tools for keeping tools or parts of the machine in good working condition or for cooling work; Safety devices specially combined with or arranged in, or specially adapted for use in connection with, machine tools
- B23Q11/0078—Safety devices protecting the operator, e.g. against accident or noise
- B23Q11/0089—Safety devices protecting the operator, e.g. against accident or noise actuating operator protecting means, e.g. closing a cover element, producing an alarm signal
-
- 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
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Machine Tool Sensing Apparatuses (AREA)
Abstract
The tool wear monitoring method based on the power measurement comprises the steps of acquiring a current tool power curve through monitoring power data of a machine tool motor, dividing the wear condition of the tool into corresponding grades through comparison with a preset power curve, and effectively prolonging the service life of the tool while guaranteeing the processing quality through different treatment modes of different wear grades, thereby reducing the maintenance cost of the machine tool and improving the production efficiency to a certain extent.
Description
Technical Field
The invention relates to the field of industrial control, in particular to a cutter wear monitoring method based on power measurement.
Background
With the progress of technical development, machining equipment is more and more complex, functional performance requirements are higher and higher, and a numerical control machine tool is main equipment for manufacturing high-end parts in the machining industry, and the intelligent degree of the numerical control machine tool determines the machining efficiency and quality. The machining precision of the numerical control machine tool is a core index of the quality of the machine tool, the cutter is a direct executive component of the machine tool, and the cutter is in direct contact with a workpiece and chips in the machining process, is subjected to severe friction and impact, is extremely easy to wear, and directly affects the performance and the machining precision of the machine tool.
Tool wear is an inevitable problem in any machining process, and the degree of tool wear is a core element in ensuring product quality in the machining process. According to statistics, the machine tool downtime is 20% of the total downtime due to cutter abrasion, and the effective monitoring system can improve the processing efficiency by 10% -50%, and reduce the production cost by 10% -40%. Therefore, the on-line monitoring of cutter abrasion is realized, the establishment of a complete cutter management system has important significance, and meanwhile, the precise grasp of cutter changing time and the guarantee of the maximum use and processing quality of the cutter are research hot spots in the field of intelligent manufacturing.
Currently, enterprises can manage the service life of tools by setting the frequency of workpieces during production operation, which is also the most common tool management and control method. In this way, there is often a situation that some tools still meeting the production and use requirements are forcibly replaced, or in extreme cases, due to the difference in states of the tools themselves or the workpieces, severe wear of the tools occurs before the specified use frequency (life expectancy) is reached, thereby affecting the product quality. It can be seen that this relatively fixed tool management strategy cannot accommodate the actual complex and variable machining process requirements, and it is difficult to simultaneously achieve both quality and cost requirements.
In addition, in the prior art, the wear degree of the cutter is also monitored by collecting information such as main shaft power, vibration, current and the like, but in general, whether cutter replacement or shutdown is needed is judged by setting upper and lower thresholds for vibration and power values in the machining process, and the service life of the cutter still cannot be effectively prolonged.
Disclosure of Invention
In order to solve the problems, the invention provides a cutter wear monitoring method based on power measurement.
The main content of the invention comprises:
a method of tool wear monitoring based on power measurements, comprising:
acquiring power data of a machine tool motor according to a set frequency;
inputting the power data into a cutter power curve model to obtain a current cutter power curve;
acquiring current processing information and acquiring a corresponding preset power curve;
obtaining the early warning grade of the current cutter according to the current cutter power curve, the corresponding preset power curve and the current processing information; the early warning level comprises an early warning level and an alarm level;
when the current early warning level is an early warning level, sending out an early warning prompt; acquiring a corresponding machine tool configuration file according to the early warning prompt, adjusting operation parameters of the machine tool according to the corresponding configuration file, and taking a current cutter power curve as a preset power curve;
when the current early warning level is an alarm level, sending out an alarm prompt; and according to the alarm prompt, acquiring an alarm type, controlling the start and stop of the machine tool according to the alarm type and the running state of the current machine tool, taking a standard power curve corresponding to the current machining type as a preset power curve, and outputting the standard power curve corresponding to the current machining type by using test data of a cutter manufacturer and daily production data as a neural network model of a training set.
Preferably, the step of acquiring power data of the machine tool motor according to the set frequency includes:
a non-contact acquisition device is arranged on a driving wire of a machine tool spindle motor; the non-contact acquisition device comprises a current transformer and a voltage transformer; the power data includes three-phase currents and three-phase voltages.
Preferably, the non-contact acquisition device further comprises a signal selection module and a signal conditioning module, wherein the input end of the signal selection module is connected with the voltage transformer and the voltage transformer, the output end of the signal selection module is connected with the signal conditioning module, and the signal conditioning module outputs current three-phase current and current three-phase voltage.
Preferably, the signal selection module comprises a processing unit, a signal selection unit and a communication unit; the signal conditioning module comprises a plurality of signal conditioning units; the signal selection chip is a digital control analog electronic switch chip CD4051, the processing unit is an MCU chip or a singlechip, the public I/O end of the signal selection chip is connected with the current transformer and the voltage transformer, the address selection end and the enabling input end of the signal selection chip are connected with the processing unit, and a plurality of signal conditioning units are selectively connected with 8 independent I/O ends of the multipath selection switch unit.
Preferably, the signal conditioning unit includes an operational amplifier and a filter, and the filter is a passive high-pass filter, an active low-pass filter, or an active band-pass filter.
Preferably, the method for obtaining the early warning grade of the current cutter according to the current cutter power curve, the corresponding preset power curve and the current processing information comprises the following steps:
acquiring current processing information, wherein the processing information comprises a processing procedure and a processing time sequence;
acquiring a corresponding preset power curve according to the current processing procedure;
acquiring a cutter power curve of a set time sequence section and a preset power curve of a corresponding set time sequence range according to the current processing time sequence;
comparing the difference value between the cutter power curve of the set time sequence section and the preset power curve of the corresponding section to obtain an abnormal difference value;
when the abnormal difference value is larger than the preset early warning value and smaller than the preset warning value, the early warning level of the current cutter is an early warning level; when the abnormal difference value is larger than a preset alarm value, the early warning level of the current cutter is an alarm level.
Preferably, according to the current processing time sequence, a cutter power curve of a set time sequence section and a preset power curve of a corresponding set time sequence range are obtained, wherein the set time sequence range refers to a time sequence range in which the processing time sequence of a first set time period from the current processing time sequence to the front is a comparison starting point, and the processing time sequence of a second set time period from the current processing time sequence to the rear is a comparison ending point.
Preferably, the comparison starting point does not exceed the starting point time sequence of the corresponding processing procedure; the comparison end point is not more than the end point time sequence of the corresponding processing procedure.
Preferably, when the abnormal difference value is smaller than a preset early warning value, the cutter power curve corresponding to the corresponding processing time sequence is used as a preset power curve.
Compared with the prior art, the cutter wear monitoring method based on power measurement has the beneficial effects that: the power data of the machine tool motor is monitored, the current cutter power curve is obtained, the corresponding grades are divided for the abrasion condition of the cutter through comparison with the preset power curve, the service life of the cutter is effectively prolonged while the processing quality is ensured through different treatment modes for different abrasion grades, the maintenance cost of the machine tool is reduced, and the production efficiency is also improved to a certain extent.
Drawings
FIG. 1 is a flow chart of the present invention.
Detailed Description
The technical scheme protected by the invention is specifically described below with reference to the accompanying drawings.
Please refer to fig. 1. The invention provides a cutter wear monitoring method based on power measurement, which adopts a non-contact mode to acquire power data of a machine tool motor, acquires the wear state of a cutter by monitoring the power change of a machine tool spindle motor, ranks the wear state of the cutter, carries out corresponding treatment according to different early warning grades, and improves the service life of the cutter on the premise of ensuring the processing quality and the processing progress.
Specifically, the tool wear monitoring method based on power measurement of the invention comprises the following steps:
firstly, acquiring power data of a motor by using a non-contact acquisition device, wherein the power data comprises three-phase current and three-phase voltage, inputting the three-phase current and the three-phase voltage into a cutter power curve model to obtain a corresponding cutter power curve, wherein the cutter power curve model is an existing power calculation mode, and the cutter power curve is a relation curve of a segmented processing time sequence and motor power, which is established for different processing procedures, such as processing of a certain processed product, and comprises a plurality of processing procedures, such as drilling, milling and the like, wherein the different processing procedures have set processing time sequences, namely processing time length, and the relation curve of time and power is established for different processing procedures.
The non-contact acquisition device comprises a current transformer and a voltage transformer for acquiring electrode current and voltage; the current transformer and the voltage transformer are arranged on a driving line of a machine tool spindle motor, and the existing line is not required to be changed; further, the non-contact acquisition device further comprises a signal selection module and a signal conditioning module, wherein the input end of the signal selection module is connected with the voltage transformer and the voltage transformer, the output end of the signal selection module is connected with the signal conditioning module, and the signal conditioning module outputs current three-phase current and current three-phase voltage, so that the power data of different machine tools or different processed products can be accurately acquired by using one set of non-contact acquisition device.
Further, the signal selection module comprises a processing unit, a signal selection unit and a communication unit; the signal conditioning module comprises a plurality of signal conditioning units; the signal selection chip is a digital control analog electronic switch chip CD4051, the processing unit is an MCU chip or a singlechip, the public I/O end of the signal selection chip is connected with the current transformer and the voltage transformer, the address selection end and the enabling input end of the signal selection chip are connected with the processing unit, and a plurality of signal conditioning units are selectively connected with 8 independent I/O ends of the multipath selection switch unit. And the signal conditioning unit comprises an operational amplifier and a filter, wherein the filter is a passive high-pass filter, an active low-pass filter or an active band-pass filter.
Acquiring a corresponding preset power curve according to current processing information while acquiring a current cutter power curve; specifically, the processing information includes a processing procedure and a processing time sequence, and a corresponding preset power curve is obtained according to the current processing procedure, namely, a preset power curve corresponding to the current processing procedure is obtained, wherein the preset power curve can be a brand new standard power curve, namely, the used cutter is an unused brand new cutter, and the standard power curve is obtained by outputting test data and daily production data of a cutter manufacturer as a neural network model of a training set; the preset power curve is a standard power curve, and the standard power curve is set to be the preset power curve for a new machine tool and a machine tool with a tool replaced; and when the tool is used for a period of time, but still can be used, setting the current tool power curve after the corresponding workpiece is processed as a preset power curve to serve as a reference curve for the next processing.
The method comprises the steps of comparing a current cutter power curve with a corresponding set power curve in real time, grading the abrasion condition of the current cutter, obtaining an early warning grade, classifying the early warning grade into an early warning grade and an alarm grade according to whether the cutter is required to be stopped and replaced, when the early warning grade is the early warning grade, stopping the cutter and replacing the cutter only when the early warning grade is reached, determining stopping time according to the subsequent processing procedures, namely, when the abnormally-occurring processing procedures are completed and the corresponding cutter is not used in the subsequent processing procedures, replacing the cutter after finishing all the processing procedures, and otherwise stopping the cutter and replacing the cutter at a proper time.
Specifically, according to the current processing time sequence, acquiring a cutter power curve of a set time sequence section and a preset power curve of a corresponding set time sequence range; comparing the difference value between the cutter power curve of the set time sequence section and the preset power curve of the corresponding section to obtain an abnormal difference value; when the abnormal difference value is larger than the preset early warning value and smaller than the preset warning value, the early warning level of the current cutter is an early warning level; when the abnormal difference value is larger than a preset alarm value, the early warning level of the current cutter is an alarm level; and when the abnormal difference value is smaller than a preset early warning value, the cutter power curve corresponding to the corresponding processing time sequence is used as a preset power curve. When the current early warning level is an early warning level, sending out an early warning prompt; acquiring a corresponding machine tool configuration file according to the early warning prompt, adjusting operation parameters of the machine tool according to the corresponding configuration file, and taking a current cutter power curve as a preset power curve; when the current early warning level is an alarm level, sending out an alarm prompt; and acquiring an alarm type according to the alarm prompt, controlling the start and stop of the machine tool according to the alarm type and the running state of the current machine tool, and taking a standard power curve corresponding to the current machining type as a preset power curve, wherein the standard power curve corresponds to the current machining type.
Further, according to the current processing time sequence, a cutter power curve of a set time sequence section and a preset power curve of a corresponding set time sequence range are obtained, wherein the set time sequence range refers to a time sequence range that the processing time sequence of a first set time period from the current processing time sequence to the front is a comparison starting point, and the processing time sequence of a second set time period from the current processing time sequence to the rear is a comparison ending point. Wherein the comparison starting point does not exceed the starting point time sequence of the corresponding processing procedure; the comparison end point is not more than the end point time sequence of the corresponding processing procedure.
The foregoing description is only illustrative of the present invention and is not intended to limit the scope of the invention, and all equivalent structures or equivalent processes or direct or indirect application in other related technical fields are included in the scope of the present invention.
Claims (9)
1. A method of tool wear monitoring based on power measurements, comprising:
acquiring power data of a machine tool motor according to a set frequency;
inputting the power data into a cutter power curve model to obtain a current cutter power curve;
acquiring current processing information and acquiring a corresponding preset power curve;
obtaining the early warning grade of the current cutter according to the current cutter power curve, the corresponding preset power curve and the current processing information; the early warning level comprises an early warning level and an alarm level;
when the current early warning level is an early warning level, sending out an early warning prompt; acquiring a corresponding machine tool configuration file according to the early warning prompt, adjusting operation parameters of the machine tool according to the corresponding configuration file, and taking a current cutter power curve as a preset power curve;
when the current early warning level is an alarm level, sending out an alarm prompt; and according to the alarm prompt, acquiring an alarm type, controlling the start and stop of the machine tool according to the alarm type and the running state of the current machine tool, taking a standard power curve corresponding to the current machining type as a preset power curve, and outputting the standard power curve corresponding to the current machining type by using test data of a cutter manufacturer and daily production data as a neural network model of a training set.
2. The method of claim 1, wherein the step of obtaining power data of a machine tool motor at a set frequency comprises:
a non-contact acquisition device is arranged on a driving wire of a machine tool spindle motor; the non-contact acquisition device comprises a current transformer and a voltage transformer; the power data includes three-phase currents and three-phase voltages.
3. The cutter wear monitoring method based on power measurement according to claim 2, wherein the non-contact acquisition device further comprises a signal selection module and a signal conditioning module, wherein the input end of the signal selection module is connected with a voltage transformer and a voltage transformer, the output end of the signal selection module is connected with the signal conditioning module, and the signal conditioning module outputs current three-phase current and current three-phase voltage.
4. A method of tool wear monitoring based on power measurements according to claim 3, wherein the signal selection module comprises a processing unit, a signal selection unit and a communication unit; the signal conditioning module comprises a plurality of signal conditioning units; the signal selection chip is a digital control analog electronic switch chip CD4051, the processing unit is an MCU chip or a singlechip, the public I/O end of the signal selection chip is connected with the current transformer and the voltage transformer, the address selection end and the enabling input end of the signal selection chip are connected with the processing unit, and a plurality of signal conditioning units are selectively connected with 8 independent I/O ends of the multipath selection switch unit.
5. The method of claim 4, wherein the signal conditioning unit comprises an operational amplifier and a filter, and the filter is a passive high pass filter, an active low pass filter, or an active band pass filter.
6. The method for monitoring tool wear based on power measurement according to claim 1, wherein obtaining the pre-warning level of the current tool according to the current tool power curve, the corresponding preset power curve and the current processing information comprises:
acquiring current processing information, wherein the processing information comprises a processing procedure and a processing time sequence;
acquiring a corresponding preset power curve according to the current processing procedure;
acquiring a cutter power curve of a set time sequence section and a preset power curve of a corresponding set time sequence range according to the current processing time sequence;
comparing the difference value between the cutter power curve of the set time sequence section and the preset power curve of the corresponding section to obtain an abnormal difference value;
when the abnormal difference value is larger than the preset early warning value and smaller than the preset warning value, the early warning level of the current cutter is an early warning level; when the abnormal difference value is larger than a preset alarm value, the early warning level of the current cutter is an alarm level.
7. The method of claim 6, wherein the tool power curve of the set time sequence period and the preset power curve of the corresponding set time sequence range are obtained according to the current processing time sequence, wherein the set time sequence range refers to a time sequence range in which the processing time sequence of the first set time period from the current processing time sequence is a comparison starting point and the processing time sequence of the second set time period from the current processing time sequence to the rear is a comparison ending point.
8. The method of claim 7, wherein the comparison starting point does not exceed the starting point timing of the corresponding machining process; the comparison end point is not more than the end point time sequence of the corresponding processing procedure.
9. The method of claim 6, wherein when the abnormal difference value is smaller than a preset pre-warning value, the tool power curve corresponding to the corresponding machining time sequence is used as a preset power curve.
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| CN202310523963.9A CN116533062A (en) | 2023-05-10 | 2023-05-10 | Cutter wear monitoring method based on power measurement |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118219064A (en) * | 2024-05-27 | 2024-06-21 | 山东迪格重工机械有限公司 | Safety alarm device for lathe based on data monitoring |
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- 2023-05-10 CN CN202310523963.9A patent/CN116533062A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118219064A (en) * | 2024-05-27 | 2024-06-21 | 山东迪格重工机械有限公司 | Safety alarm device for lathe based on data monitoring |
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