CN116992740B - Intelligent regulation and control method and system for communication base station precise component production equipment - Google Patents
Intelligent regulation and control method and system for communication base station precise component production equipment Download PDFInfo
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Abstract
The invention relates to the technical field of control methods of industrial production equipment, in particular to an intelligent regulation and control method and system of communication base station precision component production equipment, wherein a processing area which is being processed is detected at a first preset time node through an ultrasonic detector so as to reconstruct and obtain a first crack three-dimensional model diagram of the processing area corresponding to the first preset time node; if the analysis result is the second analysis result, acquiring a second crack three-dimensional model diagram corresponding to the processing area at a second preset time node; analyzing crack cracking speed and crack cracking direction of the crack according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram; and analyzing the cracks of the current processing area according to the crack cracking speed and the crack cracking direction to obtain corresponding regulation and control commands, so that the rejection rate can be reduced, the economic benefit is improved, and the intelligent processing is realized.
Description
Technical Field
The invention relates to the technical field of control methods of industrial production equipment, in particular to an intelligent regulation and control method and system of communication base station precision component production equipment.
Background
The precision parts such as an antenna base, a connector, a radiator, a lightning protector and the like of the communication base station often need to be subjected to forging technology during processing and production, because the precision parts of the communication base station are usually required to have enough strength and durability to resist challenges of external environment and long-term use, the strength and durability of the parts can be enhanced by changing the grain structure of materials and increasing the compactness of the materials, so that the precision parts can bear high load and severe conditions; and the communication base station requires highly accurate assembly and operation, so that parts thereof must have accurate sizes and shapes, and the forging process can achieve more accurate size control by controlling parameters such as temperature, pressure, time and the like in the forging process, which can ensure that the quality of the parts meets the specification requirements and can be correctly matched with other components, thus the forging process is an indispensable process step for many precision parts of the communication base station.
However, the existing forging equipment cannot adjust the processing parameters in real time according to the forging working conditions during processing, so that the intelligent degree is low, and the rejection rate is high; and in the forging process of the precision part by forging equipment, because of the influence of hammering force, forging cracks can be unavoidably generated in a forging area, when the forging cracks crack to a non-forging area, the mechanical property of the part can be greatly influenced, at the moment, the mechanical property does not meet the requirement, at the moment, the part is waste, at the moment, even if the part is continuously machined, the part is still waste, processing resources are wasted, and the production efficiency is reduced.
Disclosure of Invention
The invention overcomes the defects of the prior art and provides an intelligent regulation and control method and system for production equipment of precision parts of a communication base station.
The technical scheme adopted by the invention for achieving the purpose is as follows:
the invention discloses an intelligent regulation and control method of communication base station precision component production equipment, which comprises the following steps:
acquiring processing drawing information of a forged part, constructing an overall three-dimensional model diagram of the forged part according to the processing drawing information, and determining a plurality of processing areas and non-processing areas of the forged part based on the processing drawing; acquiring preset processing parameters of production equipment, and controlling the production equipment to sequentially process a plurality of processing areas based on the preset processing parameters;
detecting a processing area being processed at a first preset time node through an ultrasonic detector to obtain an acoustic wave signal fed back by the processing area, and reconstructing according to the acoustic wave signal to obtain a first crack three-dimensional model diagram of the processing area corresponding to the first preset time node;
constructing an abnormal crack database, and importing the first crack three-dimensional model graph into the abnormal crack database for comparison and analysis to obtain a first analysis result or a second analysis result;
If the analysis result is the first analysis result, controlling the production equipment to continuously process and produce the processing area according to the preset processing parameters; if the analysis result is the second analysis result, detecting the processing area being processed through the ultrasonic detector again at a second preset time node to obtain a second crack three-dimensional model diagram of the processing area corresponding to the second preset time node;
analyzing crack cracking speed and crack cracking direction of the crack according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram; and analyzing the crack of the current processing area according to the crack cracking speed and the crack cracking direction to obtain a corresponding regulation command, and controlling production equipment to process and produce according to the regulation command.
Further, in a preferred embodiment of the present invention, a processing area being processed is detected at a first preset time node by an ultrasonic detector, so as to obtain an acoustic wave signal fed back by the processing area, and a first crack three-dimensional model diagram corresponding to the processing area at the first preset time node is obtained by reconstructing according to the acoustic wave signal, which specifically includes:
detecting a processing area being processed through an ultrasonic detector to acquire an acoustic wave signal fed back by the processing area; the frequency domain analysis is carried out on the acoustic wave signals fed back by the processing area so as to distinguish crack signals from other frequency components and extract independent crack signals;
Filtering, gain control and threshold processing are carried out on the crack signals to obtain preprocessed crack signals; constructing a three-dimensional space, mapping each data point in the preprocessed crack signals into the three-dimensional space, and acquiring the relative coordinate value of each data point in the three-dimensional space;
coordinate conversion is carried out on the relative coordinate values according to the relative positions and directions of the ultrasonic detector and the processing area so as to obtain the real coordinate values of all data points; converting the crack signal into point cloud data based on the real coordinate values of the data points; wherein each data point represents a discrete crack surface point, the location and properties of which are determined by the crack signal;
calculating a local outlier factor value of each point cloud data through an LOF algorithm, and comparing the local outlier factor value of each point cloud data with a preset local outlier factor value; removing point cloud data corresponding to the local outlier factor value larger than the preset local outlier factor value to remove outliers, and obtaining screened point cloud data;
dividing the screened point cloud data into voxel blocks, generating models represented by the voxel blocks according to the distribution of the point cloud data in each voxel block, and combining the models represented by the voxel blocks to obtain a first crack three-dimensional model map corresponding to the processing area at a first preset time node.
Further, in a preferred embodiment of the present invention, an abnormal crack database is constructed, and the first crack three-dimensional model map is imported into the abnormal crack database for comparison and analysis, so as to obtain a first analysis result or a second analysis result, which specifically are:
acquiring an abnormal crack three-dimensional model diagram corresponding to a processing area when various abnormal working conditions occur through a big data network; constructing a database, and importing an abnormal crack three-dimensional model diagram corresponding to a processing area when various abnormal working conditions occur into the database to obtain an abnormal crack database;
importing the first crack three-dimensional model diagram into the abnormal crack database, extracting and calculating the similarity between the first crack three-dimensional model diagram and each abnormal crack three-dimensional model diagram through a feature matching algorithm, and obtaining a plurality of similarities;
constructing a sorting table, importing a plurality of the similarities into the sorting table for size sorting, and extracting the maximum similarity after sorting is completed; comparing the maximum similarity with a preset similarity;
if the maximum similarity is not greater than the preset similarity, indicating that the processing working condition of the processing area on the current processing time node is normal, generating a first analysis result; and if the maximum similarity is greater than the preset similarity, indicating that the processing working condition of the processing area on the current processing time node is abnormal, and generating a second analysis result.
Further, in a preferred embodiment of the present invention, the crack cracking speed and the crack cracking direction of the crack are analyzed according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram, specifically:
acquiring a first characteristic descriptor of the first crack three-dimensional model diagram by using a SIFT algorithm, and simultaneously acquiring a second characteristic descriptor of the second crack three-dimensional model diagram by using the SIFT algorithm;
converting the first feature descriptor into a first feature vector representation, and converting the second feature descriptor into a second feature vector representation; normalizing the first feature vector and the second feature vector to ensure that the first feature vector and the second feature vector have the same scale;
measuring the similarity between the first feature vector and the second feature vector by using cosine similarity, and marking the region with similarity larger than preset similarity as a matching region; matching the first crack three-dimensional model image and the second crack three-dimensional model image by utilizing the matching area so as to integrate the first crack three-dimensional model image and the second crack three-dimensional model image;
after integration, removing the model part of the first crack three-dimensional model graph, which is overlapped with the second crack three-dimensional model graph, and reserving the model part which is not overlapped to obtain a crack dynamic model graph;
Calculating a model volume value of the crack dynamic model diagram through a finite element analysis method, and calculating to obtain crack cracking speed based on the first preset time node, the second preset time node and the model volume value; and obtaining an edge contour curve of the crack dynamic model graph through a Soble algorithm, and analyzing according to the edge contour curve to obtain a crack direction.
Further, in a preferred embodiment of the present invention, the crack of the current processing area is analyzed according to the crack cracking speed and the crack cracking direction to obtain a corresponding regulation command, and the production equipment is controlled to perform processing and production according to the regulation command, specifically:
integrating the second crack three-dimensional model diagram into the integral three-dimensional model diagram to obtain a crack real-time state model diagram;
inputting the crack real-time state model diagram into simulation software, simulating the crack time from the crack to each non-processing area when the processing area is continuously processed under the condition of preset processing parameters based on the crack speed and the crack direction, and extracting the shortest crack time;
determining the residual processing time required by continuing to process the processing area according to the preset processing parameters; and comparing the remaining processing time with a minimum cracking time;
If the residual processing time is not more than the shortest cracking time, controlling production equipment to continuously process and produce the processing area according to preset processing parameters;
and if the residual processing time is longer than the shortest cracking time, generating a processing adjusting instruction, and adjusting preset processing parameters of production equipment according to the processing adjusting instruction.
Further, in a preferred embodiment of the present invention, if the remaining processing time is greater than the shortest cracking time, a processing adjustment instruction is generated, and the preset processing parameters of the production equipment are adjusted according to the processing adjustment instruction, which specifically includes:
if the residual processing time is longer than the shortest cracking time, acquiring the minimum processing parameters of the production equipment;
simulating the cracking time from cracking of the crack to each non-processing area when the processing area is continuously processed under the condition of minimum processing parameters based on the crack cracking speed and the crack cracking direction, and extracting the minimum cracking time;
determining the remaining processing time required for continuing to process the processing area according to the minimum processing parameters; comparing the remaining processing time to a minimum cracking time;
If the remaining processing time is not more than the minimum cracking time, controlling production equipment to process and produce the processing area according to the minimum processing parameters;
and if the remaining processing time is longer than the minimum cracking time, generating a processing stopping instruction, controlling the production equipment to stop processing and production of the forged part, and performing scrapping treatment on the forged part.
The invention discloses an intelligent regulation and control system of a production device of a precision part of a communication base station, which comprises a memory and a processor, wherein an intelligent regulation and control method program of the production device is stored in the memory, and when the intelligent regulation and control method program of the production device is executed by the processor, the following steps are realized:
acquiring processing drawing information of a forged part, constructing an overall three-dimensional model diagram of the forged part according to the processing drawing information, and determining a plurality of processing areas and non-processing areas of the forged part based on the processing drawing; acquiring preset processing parameters of production equipment, and controlling the production equipment to sequentially process a plurality of processing areas based on the preset processing parameters;
detecting a processing area being processed at a first preset time node through an ultrasonic detector to obtain an acoustic wave signal fed back by the processing area, and reconstructing according to the acoustic wave signal to obtain a first crack three-dimensional model diagram of the processing area corresponding to the first preset time node;
Constructing an abnormal crack database, and importing the first crack three-dimensional model graph into the abnormal crack database for comparison and analysis to obtain a first analysis result or a second analysis result;
if the analysis result is the first analysis result, controlling the production equipment to continuously process and produce the processing area according to the preset processing parameters; if the analysis result is the second analysis result, detecting the processing area being processed through the ultrasonic detector again at a second preset time node to obtain a second crack three-dimensional model diagram of the processing area corresponding to the second preset time node;
analyzing crack cracking speed and crack cracking direction of the crack according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram; and analyzing the crack of the current processing area according to the crack cracking speed and the crack cracking direction to obtain a corresponding regulation command, and controlling production equipment to process and produce according to the regulation command.
The invention solves the technical defects existing in the background technology, and has the following beneficial effects: detecting a processing area being processed at a first preset time node through an ultrasonic detector to reconstruct and obtain a first crack three-dimensional model diagram of the processing area corresponding to the first preset time node; constructing an abnormal crack database, and importing the first crack three-dimensional model graph into the abnormal crack database for comparison and analysis; if the analysis result is the first analysis result, controlling the production equipment to continuously process and produce the processing area according to the preset processing parameters; if the analysis result is the second analysis result, acquiring a second crack three-dimensional model diagram corresponding to the processing area at a second preset time node; analyzing crack cracking speed and crack cracking direction of the crack according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram; and analyzing the crack of the current processing area according to the crack cracking speed and the crack cracking direction to obtain a corresponding regulation command, and controlling production equipment to process and produce according to the regulation command. After the cracks appear in the forging area, the production equipment can automatically analyze corresponding regulation and control measures according to the crack conditions, so that the cracks are prevented from cracking to the non-forging area, the rejection rate is reduced, the economic benefit is improved, and intelligent processing is realized; and the processing waste can be scrapped in time, so that the processing resources can be saved, and the processing cost is effectively reduced.
Drawings
In order to more clearly illustrate the embodiments of the application or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the application, and that other embodiments of the drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a first method flow diagram of an intelligent regulation method for a communication base station precision part production facility;
FIG. 2 is a second method flow chart of an intelligent regulation method for a communication base station precision part production facility;
FIG. 3 is a third method flow chart of an intelligent regulation method of a communication base station precision component production facility;
FIG. 4 is a system block diagram of an intelligent regulation system of a communication base station precision component production facility.
Detailed Description
In order that the above-recited objects, features and advantages of the present application will be more clearly understood, a more particular description of the application will be rendered by reference to the appended drawings and appended detailed description. It should be noted that, without conflict, the embodiments of the present application and features in the embodiments may be combined with each other.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, however, the present invention may be practiced in other ways than those described herein, and therefore the scope of the present invention is not limited to the specific embodiments disclosed below.
As shown in fig. 1, the first aspect of the present invention discloses an intelligent regulation and control method for a production device of a precision component of a communication base station, which comprises the following steps:
s102: acquiring processing drawing information of a forged part, constructing an overall three-dimensional model diagram of the forged part according to the processing drawing information, and determining a plurality of processing areas and non-processing areas of the forged part based on the processing drawing; acquiring preset processing parameters of production equipment, and controlling the production equipment to sequentially process a plurality of processing areas based on the preset processing parameters;
s104: detecting a processing area being processed at a first preset time node through an ultrasonic detector to obtain an acoustic wave signal fed back by the processing area, and reconstructing according to the acoustic wave signal to obtain a first crack three-dimensional model diagram of the processing area corresponding to the first preset time node;
s106: constructing an abnormal crack database, and importing the first crack three-dimensional model graph into the abnormal crack database for comparison and analysis to obtain a first analysis result or a second analysis result;
S108: if the analysis result is the first analysis result, controlling the production equipment to continuously process and produce the processing area according to the preset processing parameters; if the analysis result is the second analysis result, detecting the processing area being processed through the ultrasonic detector again at a second preset time node to obtain a second crack three-dimensional model diagram of the processing area corresponding to the second preset time node;
s110: analyzing crack cracking speed and crack cracking direction of the crack according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram; and analyzing the crack of the current processing area according to the crack cracking speed and the crack cracking direction to obtain a corresponding regulation command, and controlling production equipment to process and produce according to the regulation command.
The processing drawing information is designed by an engineer, and the processing drawing information includes component size information, forging position information, forging parameter information and the like. The processing area is a forging area, and the non-processing area is a non-forging area. And determining preset machining parameters of the forging production equipment according to the machining drawing information, and then controlling the production equipment to sequentially machine a plurality of machining areas based on the preset machining parameters.
Detecting a processing area being processed through an ultrasonic detector at a first preset time node to acquire an acoustic wave signal fed back by the processing area, and reconstructing according to the acoustic wave signal to acquire a first crack three-dimensional model diagram of the processing area corresponding to the first preset time node, wherein the method specifically comprises the following steps of:
detecting a processing area being processed through an ultrasonic detector to acquire an acoustic wave signal fed back by the processing area; the frequency domain analysis is carried out on the acoustic wave signals fed back by the processing area so as to distinguish crack signals from other frequency components and extract independent crack signals;
filtering, gain control and threshold processing are carried out on the crack signals to obtain preprocessed crack signals; constructing a three-dimensional space, mapping each data point in the preprocessed crack signals into the three-dimensional space, and acquiring the relative coordinate value of each data point in the three-dimensional space;
coordinate conversion is carried out on the relative coordinate values according to the relative positions and directions of the ultrasonic detector and the processing area so as to obtain the real coordinate values of all data points; converting the crack signal into point cloud data based on the real coordinate values of the data points; wherein each data point represents a discrete crack surface point, the location and properties of which are determined by the crack signal;
Calculating a local outlier factor value of each point cloud data through an LOF algorithm, and comparing the local outlier factor value of each point cloud data with a preset local outlier factor value; removing point cloud data corresponding to the local outlier factor value larger than the preset local outlier factor value to remove outliers, and obtaining screened point cloud data;
dividing the screened point cloud data into voxel blocks, generating models represented by the voxel blocks according to the distribution of the point cloud data in each voxel block, and combining the models represented by the voxel blocks to obtain a first crack three-dimensional model map corresponding to the processing area at a first preset time node.
It should be noted that, the LOF algorithm is a local outlier factor algorithm, which is an algorithm for anomaly detection, and may identify an outlier in a data set and calculate an anomaly degree according to a relationship between the outlier and a neighboring data point, and the LOF algorithm compares the local outlier degree of a data point with the density of its neighboring data point based on a concept of local density. Local outlier value refers to the ratio of the local reachable density of a data point to the average local reachable density of its neighbors, which represents the degree of outliers of a data point relative to its neighbors, higher local outlier values indicating that a data point is more likely to be an outlier, while lower values indicate that the data point is closer to normal data. Outliers can be removed through an LOF algorithm, so that more accurate data are obtained, a first crack three-dimensional model diagram with higher precision is constructed, and the actual state of cracks in a processing area is restored more truly.
The method is characterized in that the method comprises the steps of obtaining the sound wave signal of the processing area and combining the reconstruction mode of the point cloud, so that a first crack three-dimensional model diagram in the processing area is quickly constructed and obtained, and compared with an image reconstruction mode, the method does not need to carry out complex and large amount of image processing operation, and therefore the robustness of the system and the modeling efficiency can be improved.
The method comprises the steps of constructing an abnormal crack database, and importing the first crack three-dimensional model diagram into the abnormal crack database for comparison and analysis to obtain a first analysis result or a second analysis result, as shown in fig. 2, specifically comprising the following steps:
s202: acquiring an abnormal crack three-dimensional model diagram corresponding to a processing area when various abnormal working conditions occur through a big data network; constructing a database, and importing an abnormal crack three-dimensional model diagram corresponding to a processing area when various abnormal working conditions occur into the database to obtain an abnormal crack database;
s204: importing the first crack three-dimensional model diagram into the abnormal crack database, extracting and calculating the similarity between the first crack three-dimensional model diagram and each abnormal crack three-dimensional model diagram through a feature matching algorithm, and obtaining a plurality of similarities;
s206: constructing a sorting table, importing a plurality of the similarities into the sorting table for size sorting, and extracting the maximum similarity after sorting is completed; comparing the maximum similarity with a preset similarity;
S208: if the maximum similarity is not greater than the preset similarity, indicating that the processing working condition of the processing area on the current processing time node is normal, generating a first analysis result; and if the maximum similarity is greater than the preset similarity, indicating that the processing working condition of the processing area on the current processing time node is abnormal, and generating a second analysis result.
It should be noted that, during forging, forging cracks are inevitably generated in the forging area under the action of impact force or hammering force, and the forging cracks are generally classified into normal cracks or abnormal cracks according to property distinction, and the normal cracks usually appear in the stress concentration part of the forging area, which is caused by the fact that the material is subjected to larger stress concentration in the forging process; abnormal cracks may occur at the edges or protrusions of the forged region, such cracks typically being caused by imperfections or non-uniformities in the material. Normal cracks generally exhibit a more regular morphology, such as straight or curved; abnormal cracks may exhibit irregular morphology such as branching, propagation, or crossing. Normal cracks usually exist in a small amount, and are distributed uniformly; an abnormal crack may occur in a large number of cracks or in a case of aggregation. Normal cracks are usually shallower and do not go too far into the interior of the material; the abnormal cracks may then penetrate into the material interior and even extend over the entire cross-section.
It should be noted that, the feature matching algorithm calculates the similarity by extracting and matching feature points of the two models, and common features include shape descriptors, normal vectors, curvatures, and the like, and the similarity between the two models can be evaluated by calculating the number and quality of the matched feature points. If the maximum similarity is not greater than the preset similarity, indicating that the forging crack appearing in the processing area on the current processing time node belongs to a normal crack, generating a first analysis result, and controlling production equipment to continuously process and produce the processing area according to preset processing parameters. If the maximum similarity is greater than the preset similarity, the forging crack in the processing area on the current processing time node is an abnormal crack, and further analysis of the abnormal crack is needed at the moment, and a second analysis result is generated. By the method, whether the forging working condition is normal can be automatically identified.
The crack cracking speed and the crack cracking direction of the crack are analyzed according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram, and the method specifically comprises the following steps:
acquiring a first characteristic descriptor of the first crack three-dimensional model diagram by using a SIFT algorithm, and simultaneously acquiring a second characteristic descriptor of the second crack three-dimensional model diagram by using the SIFT algorithm;
It should be noted that, the SIFT (scale invariant feature transform) algorithm is a classical computer vision algorithm for detecting and describing feature descriptors in a model, by constructing a gaussian pyramid of the model, extreme points (key points) of the model at different scales are detected, and feature descriptors of local areas are used to describe image areas around the key points, which have invariance to rotation, scaling and illumination changes.
Converting the first feature descriptor into a first feature vector representation, and converting the second feature descriptor into a second feature vector representation; normalizing the first feature vector and the second feature vector to ensure that the first feature vector and the second feature vector have the same scale;
measuring the similarity between the first feature vector and the second feature vector by using cosine similarity, and marking the region with similarity larger than preset similarity as a matching region; matching the first crack three-dimensional model image and the second crack three-dimensional model image by utilizing the matching area so as to integrate the first crack three-dimensional model image and the second crack three-dimensional model image;
It should be noted that each feature descriptor is converted into a feature vector representation. Typically, a feature descriptor will be represented as a vector of fixed length, where each element represents a feature attribute. The feature vectors are normalized to ensure that they have the same scale. The vector is normalized using the L2 norm, i.e., each element is divided by the L2 norm of the vector. Cosine similarity is used to measure the similarity between two feature vectors. The cosine similarity measures the cosine value of the included angle of the two vectors, and the value range is between [ -1,1 ]. And selecting a specific threshold value to determine the matched characteristic points or characteristic areas according to the cosine similarity calculation result. Features with similarity higher than a threshold may be considered a match.
After integration, removing the model part of the first crack three-dimensional model graph, which is overlapped with the second crack three-dimensional model graph, and reserving the model part which is not overlapped to obtain a crack dynamic model graph;
calculating a model volume value of the crack dynamic model diagram through a finite element analysis method, and calculating to obtain crack cracking speed based on the first preset time node, the second preset time node and the model volume value; and obtaining an edge contour curve of the crack dynamic model graph through a Soble algorithm, and analyzing according to the edge contour curve to obtain a crack direction.
It should be noted that, by using a finite element mesh model with a discrete crack dynamic model diagram, the volume of each element is determined by calculating the geometry of each finite element, and in general, the common finite element shape includes two-dimensional elements such as triangles and quadrilaterals, and three-dimensional elements such as tetrahedrons and hexahedrons, and the volumes of all the finite element elements are summed up to obtain the volume of the whole model. The Soble algorithm (Sobel algorithm) is a common edge detection algorithm used for detecting edges in a graph, and based on the gray level difference of the graph, the position of the edges is determined by calculating the gradient strength of pixel points, the crack tip point in the edge profile curve of a crack dynamic model graph is extracted, and then the crack direction is analyzed according to the displacement condition of the crack tip point. According to the method, the crack cracking speed and the crack cracking direction of the crack can be analyzed according to the change condition of the crack in the preset time period.
The method comprises the steps of analyzing the crack of the current processing area according to the crack cracking speed and the crack cracking direction to obtain a corresponding regulation command, and controlling production equipment to process and produce according to the regulation command, as shown in fig. 3, specifically comprising the following steps:
S302: integrating the second crack three-dimensional model diagram into the integral three-dimensional model diagram to obtain a crack real-time state model diagram;
s304: inputting the crack real-time state model diagram into simulation software, simulating the crack time from the crack to each non-processing area when the processing area is continuously processed under the condition of preset processing parameters based on the crack speed and the crack direction, and extracting the shortest crack time;
s306: determining the residual processing time required by continuing to process the processing area according to the preset processing parameters; and comparing the remaining processing time with a minimum cracking time;
s308: if the residual processing time is not more than the shortest cracking time, controlling production equipment to continuously process and produce the processing area according to preset processing parameters;
s310: and if the residual processing time is longer than the shortest cracking time, generating a processing adjusting instruction, and adjusting preset processing parameters of production equipment according to the processing adjusting instruction.
The processing parameters include hammering force, hammering speed, forging temperature, forging time, etc. And integrating the second crack three-dimensional model diagram into the whole three-dimensional model diagram through industrial three-dimensional simulation software such as SolidWorks, proe and the like to obtain a crack real-time state model diagram. Setting model simulation parameters according to preset processing parameters, crack cracking speed and crack cracking direction, simulating the cracking time from the current crack to each non-processing area through industrial three-dimensional simulation software, and then extracting the shortest cracking time; if the remaining processing time is not longer than the shortest cracking time, the fact that after the processing area is processed and forged is achieved is that the crack still cannot crack on the non-forging area of the forged part, the performance of the non-forging area in the forged workpiece cannot be affected, and at the moment, the production equipment is controlled to continuously process and produce the processing area according to preset processing parameters. By the method, whether cracks in the forging area can crack into the non-forging area can be analyzed, so that whether machining parameters need to be regulated and controlled is analyzed, intelligent machining production is realized, and the product yield can be improved.
If the remaining processing time is longer than the shortest cracking time, a processing adjusting instruction is generated, and preset processing parameters of production equipment are adjusted according to the processing adjusting instruction, specifically:
if the residual processing time is longer than the shortest cracking time, acquiring the minimum processing parameters of the production equipment;
simulating the cracking time from cracking of the crack to each non-processing area when the processing area is continuously processed under the condition of minimum processing parameters based on the crack cracking speed and the crack cracking direction, and extracting the minimum cracking time;
determining the remaining processing time required for continuing to process the processing area according to the minimum processing parameters; comparing the remaining processing time to a minimum cracking time;
if the remaining processing time is not more than the minimum cracking time, controlling production equipment to process and produce the processing area according to the minimum processing parameters;
and if the remaining processing time is longer than the minimum cracking time, generating a processing stopping instruction, controlling the production equipment to stop processing and production of the forged part, and performing scrapping treatment on the forged part.
If the remaining processing time is longer than the shortest cracking time, it means that if the processing is completed in the processing area according to the preset processing parameters, the crack will still crack to the non-forging area of the forged part, thereby affecting the performance of the non-forging area in the forged workpiece, and at this time, the preset processing parameters need to be regulated and controlled to avoid the crack from cracking to the non-forging area. Such as by reducing the hammer force to avoid cracking of the crack into the non-forged region. Specifically, model simulation parameters are set according to the minimum processing parameters, the crack cracking speed and the crack cracking direction, the cracking time from the current crack to each non-processing area is simulated through industrial three-dimensional simulation software, and then the minimum cracking time is extracted.
If the remaining processing time is not longer than the minimum cracking time, it is indicated that after the hammering force is adjusted to the minimum, the crack will not crack on the non-forging area of the forging part, and the performance of the non-forging area in the forging workpiece will not be affected.
If the remaining processing time is longer than the minimum cracking time, the processing and production of the forging area are performed in the mode of the minimum hammering force even though the hammering force is reduced and is adjusted to the minimum, the crack still cracks to the non-processing area, the processing and production of the forging part are still waste even if the processing of the forging part is continued, and at the moment, the production equipment is immediately controlled to stop the continuous processing and production of the forging part and discard the forging part. Therefore, the method can timely discard the processing waste, save processing resources and effectively reduce processing cost.
In addition, the intelligent regulation and control method of the communication base station precision component production equipment further comprises the following steps:
acquiring a corresponding crack environment response constant when the environmental factors are combined through a big data network, constructing a knowledge graph, and importing the corresponding crack environment response constant when the environmental factors are combined into the knowledge graph;
collecting real-time processing environment factors of production equipment during processing, importing the real-time processing environment factors into the knowledge graph, and calculating the association degree between the real-time processing environment factors and a preset environment factor combination by a gray association analysis method to obtain a plurality of association degrees;
constructing a sequence table, importing a plurality of relevancy levels into the sequence table for sequencing, extracting the maximum relevancy level after sequencing is completed, acquiring a preset environment factor combination corresponding to the maximum relevancy level, and determining a real-time crack environment response constant of production equipment under a real-time processing environment factor according to the preset environment factor combination corresponding to the maximum relevancy level;
comparing the real-time crack environment response constant with a first preset crack environment response constant and a second preset crack environment response constant; wherein the first preset crack environment response constant is less than the second preset crack environment response constant;
If the real-time crack environment response constant is larger than the first preset crack environment response constant and smaller than the second preset crack environment response constant, enabling the production equipment to continuously process and produce the current processing area according to preset processing parameters;
if the real-time crack environment response constant is smaller than or equal to the first preset crack environment response constant, processing and producing the current processing area after the preset processing parameters of the production equipment are increased;
and if the real-time crack environment response constant is larger than or equal to the second preset crack environment response constant, processing and producing the current processing area after the preset processing parameters of the production equipment are reduced.
The crack environment response constant is a parameter describing the correlation of crack growth and environmental factors. It represents the relationship between crack initiation rate and environmental factors (e.g., humidity, temperature, dust level, etc.). The crack environment response constant, generally denoted as C, is capable of quantifying the contribution of an environmental factor to the crack initiation rate and is used to predict the crack propagation behavior of a material under certain environmental factor combinations, the value of the crack environment response constant being related to different environmental factors and the properties of the material. If the temperature is higher within a certain range, the environmental response constant of the crack is larger, and the cracking speed of the crack is larger. If the real-time crack environment response constant is larger than the first preset crack environment response constant and smaller than the second preset crack environment response constant, the value of the crack speed under the current processing environment is ideal, and the production equipment can continue to process and produce the current processing area according to the preset processing parameters. If the real-time crack environment response constant is smaller than or equal to the first preset crack environment response constant, the crack speed of the crack is lower under the current processing environment, and the preset processing parameters of the production equipment are adjusted to be higher at the moment, and then the current processing area is processed and produced, if the hammering speed can be properly increased, the production and processing efficiency can be improved. If the real-time crack environment response constant is greater than or equal to the second preset crack environment response constant, which indicates that the crack speed of the crack is higher under the current processing environment, the preset processing parameters of the production equipment are reduced, and then the current processing area is processed and produced, if the hammering speed can be properly reduced, the crack speed of the crack is slowed down, the crack is prevented from cracking to the non-forging area, and the rejection rate is reduced. Therefore, the intelligent adjustment of the processing parameters in the forging processing process is realized by the method, the production efficiency can be improved to the greatest extent, and the rejection rate is reduced.
In addition, the intelligent regulation and control method of the communication base station precision component production equipment further comprises the following steps:
after the processing area is processed and forged, detecting the forged processing area through an ultrasonic detector to obtain a real-time three-dimensional model diagram in the processing area;
extracting features of the real-time three-dimensional model graph, extracting to obtain cracks existing in the real-time three-dimensional model graph, counting the total volume of the cracks existing in the real-time three-dimensional model graph, and carrying out ratio operation on the total volume of the cracks existing in the real-time three-dimensional model graph and the total volume of the real-time three-dimensional model graph to obtain the crack occupancy rate; comparing the crack occupancy rate with a preset occupancy rate;
if the crack occupancy rate is not greater than the preset occupancy rate, controlling production equipment to process the next processing area;
if the crack occupancy rate is larger than the preset occupancy rate, acquiring processing elements of the processing area in other process steps according to the processing drawing information, and integrating the processing elements into the real-time three-dimensional model diagram to obtain a simulated three-dimensional model diagram;
obtaining the total volume of the residual cracks of the simulated three-dimensional model diagram, and carrying out ratio processing on the total volume of the residual cracks and the total volume of the simulated three-dimensional model diagram to obtain the simulated crack occupancy rate; comparing the simulated crack occupancy rate with a preset occupancy rate;
If the simulated crack occupancy rate is not greater than the preset occupancy rate, controlling production equipment to process the next processing area; and if the simulated crack duty ratio is larger than the preset duty ratio, stopping processing the forged part, and performing scrapping treatment on the forged part.
After forging a certain processing area, if the crack occupancy rate of the processing area is too large, the mechanical performance of the processing area does not reach the standard, and after the forging process, the forged part may also undergo other process steps such as a punching process, a grinding process and the like, so that if the crack occupancy rate is greater than the preset occupancy rate, punching parameters (processing elements) such as the punching process can be obtained according to processing drawing information, and the processing elements are integrated into the real-time three-dimensional model diagram through three-dimensional industrial software to obtain a simulated three-dimensional model diagram, namely a simulated three-dimensional model diagram of the forged part after the punching process. If the simulated crack occupancy rate is not greater than the preset occupancy rate, the fact that even if the crack occupancy rate of the machining area is too large is indicated, a part of cracks are eliminated after the punching process, so that the crack occupancy rate of the machining area is reduced to be within a proper range, at the moment, the mechanical property of the forged part is qualified after the punching process, and at the moment, the production equipment is controlled to machine the next machining area. If the simulated crack duty ratio is larger than the preset duty ratio, the mechanical property of the forged part is still unqualified even after other process steps are carried out, and the part is immediately scrapped at the moment, so that processing resources can be saved, and the processing cost can be effectively reduced.
As shown in fig. 4, the second aspect of the present invention discloses an intelligent regulation system for a production device of a precision component of a communication base station, the intelligent regulation system includes a memory 15 and a processor 16, the memory 15 stores an intelligent regulation method program of the production device, and when the intelligent regulation method program of the production device is executed by the processor 16, the following steps are implemented:
acquiring processing drawing information of a forged part, constructing an overall three-dimensional model diagram of the forged part according to the processing drawing information, and determining a plurality of processing areas and non-processing areas of the forged part based on the processing drawing; acquiring preset processing parameters of production equipment, and controlling the production equipment to sequentially process a plurality of processing areas based on the preset processing parameters;
detecting a processing area being processed at a first preset time node through an ultrasonic detector to obtain an acoustic wave signal fed back by the processing area, and reconstructing according to the acoustic wave signal to obtain a first crack three-dimensional model diagram of the processing area corresponding to the first preset time node;
constructing an abnormal crack database, and importing the first crack three-dimensional model graph into the abnormal crack database for comparison and analysis to obtain a first analysis result or a second analysis result;
If the analysis result is the first analysis result, controlling the production equipment to continuously process and produce the processing area according to the preset processing parameters; if the analysis result is the second analysis result, detecting the processing area being processed through the ultrasonic detector again at a second preset time node to obtain a second crack three-dimensional model diagram of the processing area corresponding to the second preset time node;
analyzing crack cracking speed and crack cracking direction of the crack according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram; and analyzing the crack of the current processing area according to the crack cracking speed and the crack cracking direction to obtain a corresponding regulation command, and controlling production equipment to process and produce according to the regulation command.
In the several embodiments provided by the present application, it should be understood that the disclosed apparatus and method may be implemented in other ways. The above described device embodiments are only illustrative, e.g. the division of the units is only one logical function division, and there may be other divisions in practice, such as: multiple units or components may be combined or may be integrated into another system, or some features may be omitted, or not performed. In addition, the various components shown or discussed may be coupled or directly coupled or communicatively coupled to each other via some interface, whether indirectly coupled or communicatively coupled to devices or units, whether electrically, mechanically, or otherwise.
The units described above as separate components may or may not be physically separate, and components shown as units may or may not be physical units; can be located in one place or distributed to a plurality of network units; some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
In addition, each functional unit in each embodiment of the present invention may be integrated in one processing unit, or each unit may be separately used as one unit, or two or more units may be integrated in one unit; the integrated units may be implemented in hardware or in hardware plus software functional units.
Those of ordinary skill in the art will appreciate that: all or part of the steps for implementing the above method embodiments may be implemented by hardware related to program instructions, and the foregoing program may be stored in a computer readable storage medium, where the program, when executed, performs steps including the above method embodiments; and the aforementioned storage medium includes: a mobile storage device, a Read-Only Memory (ROM), a random access Memory (RAM, random Access Memory), a magnetic disk or an optical disk, or the like, which can store program codes.
Alternatively, the above-described integrated units of the present invention may be stored in a computer-readable storage medium if implemented in the form of software functional modules and sold or used as separate products. Based on such understanding, the technical solutions of the embodiments of the present invention may be embodied in essence or a part contributing to the prior art in the form of a software product stored in a storage medium, including several instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to execute all or part of the methods of the embodiments of the present invention. And the aforementioned storage medium includes: a removable storage device, ROM, RAM, magnetic or optical disk, or other medium capable of storing program code.
The foregoing is merely illustrative embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily think about variations or substitutions within the technical scope of the present invention, and the invention should be covered. Therefore, the protection scope of the invention is subject to the protection scope of the claims.
Claims (7)
1. An intelligent regulation and control method for communication base station precision component production equipment is characterized by comprising the following steps:
acquiring processing drawing information of a forged part, constructing an overall three-dimensional model diagram of the forged part according to the processing drawing information, and determining a plurality of processing areas and non-processing areas of the forged part based on the processing drawing; acquiring preset processing parameters of production equipment, and controlling the production equipment to sequentially process a plurality of processing areas based on the preset processing parameters;
detecting a processing area being processed at a first preset time node through an ultrasonic detector to obtain an acoustic wave signal fed back by the processing area, and reconstructing according to the acoustic wave signal to obtain a first crack three-dimensional model diagram of the processing area corresponding to the first preset time node;
constructing an abnormal crack database, and importing the first crack three-dimensional model graph into the abnormal crack database for comparison and analysis to obtain a first analysis result or a second analysis result;
if the analysis result is the first analysis result, controlling the production equipment to continuously process and produce the processing area according to the preset processing parameters; if the analysis result is the second analysis result, detecting the processing area being processed through the ultrasonic detector again at a second preset time node to obtain a second crack three-dimensional model diagram of the processing area corresponding to the second preset time node;
Analyzing crack cracking speed and crack cracking direction of the crack according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram; and analyzing the crack of the current processing area according to the crack cracking speed and the crack cracking direction to obtain a corresponding regulation command, and controlling production equipment to process and produce according to the regulation command.
2. The intelligent regulation and control method of the communication base station precision component production equipment according to claim 1, wherein the method is characterized in that a processing area being processed is detected at a first preset time node through an ultrasonic detector to obtain an acoustic wave signal fed back by the processing area, and a first crack three-dimensional model diagram corresponding to the processing area at the first preset time node is obtained by reconstructing the acoustic wave signal, specifically:
detecting a processing area being processed through an ultrasonic detector to acquire an acoustic wave signal fed back by the processing area; the frequency domain analysis is carried out on the acoustic wave signals fed back by the processing area so as to distinguish crack signals from other frequency components and extract independent crack signals;
filtering, gain control and threshold processing are carried out on the crack signals to obtain preprocessed crack signals; constructing a three-dimensional space, mapping each data point in the preprocessed crack signals into the three-dimensional space, and acquiring the relative coordinate value of each data point in the three-dimensional space;
Coordinate conversion is carried out on the relative coordinate values according to the relative positions and directions of the ultrasonic detector and the processing area so as to obtain the real coordinate values of all data points; converting the crack signal into point cloud data based on the real coordinate values of the data points; wherein each data point represents a discrete crack surface point, the location and properties of which are determined by the crack signal;
calculating a local outlier factor value of each point cloud data through an LOF algorithm, and comparing the local outlier factor value of each point cloud data with a preset local outlier factor value; removing point cloud data corresponding to the local outlier factor value larger than the preset local outlier factor value to remove outliers, and obtaining screened point cloud data;
dividing the screened point cloud data into voxel blocks, generating models represented by the voxel blocks according to the distribution of the point cloud data in each voxel block, and combining the models represented by the voxel blocks to obtain a first crack three-dimensional model map corresponding to the processing area at a first preset time node.
3. The intelligent regulation and control method of the communication base station precise component production equipment according to claim 1, wherein an abnormal crack database is constructed, and the first crack three-dimensional model diagram is imported into the abnormal crack database for comparison and analysis to obtain a first analysis result or a second analysis result, specifically comprising the following steps:
Acquiring an abnormal crack three-dimensional model diagram corresponding to a processing area when various abnormal working conditions occur through a big data network; constructing a database, and importing an abnormal crack three-dimensional model diagram corresponding to a processing area when various abnormal working conditions occur into the database to obtain an abnormal crack database;
importing the first crack three-dimensional model diagram into the abnormal crack database, extracting and calculating the similarity between the first crack three-dimensional model diagram and each abnormal crack three-dimensional model diagram through a feature matching algorithm, and obtaining a plurality of similarities;
constructing a sorting table, importing a plurality of the similarities into the sorting table for size sorting, and extracting the maximum similarity after sorting is completed; comparing the maximum similarity with a preset similarity;
if the maximum similarity is not greater than the preset similarity, indicating that the processing working condition of the processing area on the current processing time node is normal, generating a first analysis result; and if the maximum similarity is greater than the preset similarity, indicating that the processing working condition of the processing area on the current processing time node is abnormal, and generating a second analysis result.
4. The intelligent regulation and control method of the communication base station precision component production equipment according to claim 1, wherein the crack cracking speed and the crack cracking direction of the crack are analyzed according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram, specifically:
Acquiring a first characteristic descriptor of the first crack three-dimensional model diagram by using a SIFT algorithm, and simultaneously acquiring a second characteristic descriptor of the second crack three-dimensional model diagram by using the SIFT algorithm;
converting the first feature descriptor into a first feature vector representation, and converting the second feature descriptor into a second feature vector representation; normalizing the first feature vector and the second feature vector to ensure that the first feature vector and the second feature vector have the same scale;
measuring the similarity between the first feature vector and the second feature vector by using cosine similarity, and marking the region with similarity larger than preset similarity as a matching region; matching the first crack three-dimensional model image and the second crack three-dimensional model image by utilizing the matching area so as to integrate the first crack three-dimensional model image and the second crack three-dimensional model image;
after integration, removing the model part of the first crack three-dimensional model graph, which is overlapped with the second crack three-dimensional model graph, and reserving the model part which is not overlapped to obtain a crack dynamic model graph;
calculating a model volume value of the crack dynamic model diagram through a finite element analysis method, and calculating to obtain crack cracking speed based on the first preset time node, the second preset time node and the model volume value; and obtaining an edge contour curve of the crack dynamic model graph through a Soble algorithm, and analyzing according to the edge contour curve to obtain a crack direction.
5. The intelligent regulation and control method of the production equipment of the precision parts of the communication base station according to claim 1, wherein the analysis of the cracks of the current processing area according to the crack cracking speed and the crack cracking direction is performed to obtain corresponding regulation and control commands, and the production equipment is controlled to perform processing and production according to the regulation and control commands, specifically:
integrating the second crack three-dimensional model diagram into the integral three-dimensional model diagram to obtain a crack real-time state model diagram;
inputting the crack real-time state model diagram into simulation software, simulating the crack time from the crack to each non-processing area when the processing area is continuously processed under the condition of preset processing parameters based on the crack speed and the crack direction, and extracting the shortest crack time;
determining the residual processing time required by continuing to process the processing area according to the preset processing parameters; and comparing the remaining processing time with a minimum cracking time;
if the residual processing time is not more than the shortest cracking time, controlling production equipment to continuously process and produce the processing area according to preset processing parameters;
And if the residual processing time is longer than the shortest cracking time, generating a processing adjusting instruction, and adjusting preset processing parameters of production equipment according to the processing adjusting instruction.
6. The intelligent regulation and control method of a production device of a precision component of a communication base station according to claim 5, wherein if the remaining processing time is longer than the shortest cracking time, a processing adjustment instruction is generated, and the preset processing parameters of the production device are adjusted according to the processing adjustment instruction, specifically:
if the residual processing time is longer than the shortest cracking time, acquiring the minimum processing parameters of the production equipment;
simulating the cracking time from cracking of the crack to each non-processing area when the processing area is continuously processed under the condition of minimum processing parameters based on the crack cracking speed and the crack cracking direction, and extracting the minimum cracking time;
determining the remaining processing time required for continuing to process the processing area according to the minimum processing parameters; comparing the remaining processing time to a minimum cracking time;
if the remaining processing time is not more than the minimum cracking time, controlling production equipment to process and produce the processing area according to the minimum processing parameters;
And if the remaining processing time is longer than the minimum cracking time, generating a processing stopping instruction, controlling the production equipment to stop processing and production of the forged part, and performing scrapping treatment on the forged part.
7. The intelligent regulation and control system of the production equipment of the precise component of the communication base station is characterized by comprising a memory and a processor, wherein an intelligent regulation and control method program of the production equipment is stored in the memory, and when the intelligent regulation and control method program of the production equipment is executed by the processor, the following steps are realized:
acquiring processing drawing information of a forged part, constructing an overall three-dimensional model diagram of the forged part according to the processing drawing information, and determining a plurality of processing areas and non-processing areas of the forged part based on the processing drawing; acquiring preset processing parameters of production equipment, and controlling the production equipment to sequentially process a plurality of processing areas based on the preset processing parameters;
detecting a processing area being processed at a first preset time node through an ultrasonic detector to obtain an acoustic wave signal fed back by the processing area, and reconstructing according to the acoustic wave signal to obtain a first crack three-dimensional model diagram of the processing area corresponding to the first preset time node;
Constructing an abnormal crack database, and importing the first crack three-dimensional model graph into the abnormal crack database for comparison and analysis to obtain a first analysis result or a second analysis result;
if the analysis result is the first analysis result, controlling the production equipment to continuously process and produce the processing area according to the preset processing parameters; if the analysis result is the second analysis result, detecting the processing area being processed through the ultrasonic detector again at a second preset time node to obtain a second crack three-dimensional model diagram of the processing area corresponding to the second preset time node;
analyzing crack cracking speed and crack cracking direction of the crack according to the first crack three-dimensional model diagram and the second crack three-dimensional model diagram; and analyzing the crack of the current processing area according to the crack cracking speed and the crack cracking direction to obtain a corresponding regulation command, and controlling production equipment to process and produce according to the regulation command.
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