CN117806231B - Machine tool operation and machining control system and method based on Internet of things - Google Patents
Machine tool operation and machining control system and method based on Internet of things Download PDFInfo
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- 238000003754 machining Methods 0.000 title claims abstract description 132
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- 238000004458 analytical method Methods 0.000 claims description 71
- 238000011156 evaluation Methods 0.000 claims description 65
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- 230000007547 defect Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 2
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- 238000009740 moulding (composite fabrication) Methods 0.000 description 1
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Abstract
The invention relates to the technical field of machining control, in particular to a machine tool operation machining control system and method based on the Internet of things.
Description
Technical Field
The invention relates to the technical field of machining control, in particular to a machine tool operation machining control system and method based on the Internet of things.
Background
The machine tool is a mechanical device for processing a workpiece, is one of the most widely used devices in the manufacturing industry, is widely applied to various fields such as automobile manufacturing, aerospace, die manufacturing, household appliances and the like, is a common processing mode in the manufacturing industry, and is used for cutting, forming, punching, grinding and the like, and the machine tool is used for processing the workpiece into parts or products with required shapes and sizes, so that the machine tool has important significance in improving the production efficiency, reducing the cost and ensuring the product quality.
The patent name is a technical scheme published by Chinese patent publication of a processing method (application number is CN 202011185297.5) for processing a workpiece by utilizing a numerical control machine tool, the scheme is characterized in that a cylindrical workpiece is placed in a to-be-processed area after being sheared by operating external cutting equipment, the workpiece in the to-be-processed area is moved into the numerical control machine tool by utilizing a mechanical arm, the workpiece is fixed in the numerical control machine tool by utilizing a three-jaw chuck, meanwhile, the cylindrical workpiece is subjected to tool setting by manually operating the numerical control machine tool, the working efficiency of the workpiece processed by the equipment is improved, and the defects still exist, and are particularly represented in the following aspects: 1. according to the scheme, the three-jaw chuck is used for fixing a workpiece in the numerical control machine tool, so that the workpiece can be kept at a stable position in the machining process, but detection of other factors of the workpiece, such as workpiece size and chuck clamping force, can be omitted, workpiece re-clamping and machining program adjustment can be frequently performed, production efficiency is affected, machining precision is low, and machining period and production cost are increased.
2. The scheme does not relate to detection of machining precision conformity to a workpiece, machining errors or deviations can not be found and corrected in time in the production process, subsequent machining is scrapped, production efficiency is reduced, meanwhile, if the machined workpiece is not detected to be in use through the detection of machining precision conformity, reworking or scrapping can be needed once quality problems are found, and resource waste and production cost increase are caused.
Disclosure of Invention
In order to overcome the defects in the background technology, the embodiment of the invention provides a machine tool operation and processing control system based on the Internet of things, which can effectively solve the problems related to the background technology.
The aim of the invention can be achieved by the following technical scheme: the invention provides a machine tool operation and processing control system based on the Internet of things, which comprises the following steps: and the workpiece fixing detection module is used for detecting the position conformity, the size conformity and the clamping force of the workpiece.
And the workpiece fixing analysis module is used for analyzing and obtaining a workpiece adjustment demand coefficient according to the position conformity, the size conformity and the clamping force of the workpiece so as to judge whether the workpiece needs to be adjusted.
And the workpiece adjusting module is used for classifying and adjusting the workpieces according to the position conformity, the size conformity and the clamping force of the workpieces.
The workpiece processing planning module is used for obtaining a workpiece processing requirement model through drawing scanning, and further selecting a processing path according to a workpiece part to be processed.
The processing parameter detection and analysis module is used for detecting the processing parameters of the first part of the workpiece in real time according to the processing path of the workpiece, analyzing to obtain the processing precision coincidence degree of the first part of the workpiece, and further processing each part of the workpiece in sequence to obtain the processing precision coincidence degree of each part of the workpiece, wherein the processing parameters comprise the size coincidence degree and the surface roughness.
The secondary processing analysis module is used for comparing the processing precision coincidence degree of each part of the workpiece with a preset processing precision coincidence degree threshold value to obtain coincidence degree deviation of each part of the workpiece, and further judging whether the workpiece needs secondary processing or not, so that secondary processing compensation quantity of each part of the workpiece is obtained.
The standard evaluation index analysis module is used for analyzing and obtaining the standard evaluation index of the workpiece according to the machining precision coincidence degree of each part of the workpiece, and comparing the standard evaluation index with the preset standard evaluation index range corresponding to each machining evaluation grade, so that the machining evaluation grade of the workpiece is obtained.
And the management database is used for storing the design coordinates of each position point of the workpiece and the standard model of the workpiece.
Preferably, the specific analysis process of the workpiece fixing detection module is as follows: the method comprises the steps of firstly, scanning a workpiece to be processed through a laser scanner to obtain three-dimensional point cloud data of the surface of the workpiece, reconstructing a three-dimensional model of the workpiece according to the three-dimensional point cloud data of the surface of the workpiece, marking the three-dimensional model as a workpiece three-dimensional model, simultaneously taking a plurality of position points on the surface of the workpiece according to a set distance, reading three-dimensional coordinates of each position point of the three-dimensional model of the workpiece, and marking the three-dimensional coordinates asWhereinRepresent the firstThe number of the point of the position,Reading the design coordinates of each position point of the workpiece from the management databaseSubstituting it into formulaObtaining the position conformity of the workpiece, which is recorded asWhereinRepresenting the number of location points.
Reading a workpiece standard model from a management database, superposing the workpiece standard model and the workpiece three-dimensional model to obtain a workpiece three-dimensional model and an overlapped part of the workpiece standard model, extracting the volume of the overlapped part, comparing the volume of the overlapped part with the volume of the workpiece standard model to obtain the size conformity of the workpiece, and recording as。
Third, the clamping force when the workpiece is clamped is detected by a force sensor arranged on the clamping device and is recorded as。
Preferably, the specific analysis process of the workpiece fixing analysis module is as follows: the first step, the position coincidence degree of the workpiece is respectively readCompliance of dimensionsClamping forceBy the formulaObtaining the workpiece adjustment demand coefficientWhereinIndicating the set standard clamping force to be applied,Respectively representing the weight factors of the set position conformity, the size conformity and the clamping force,Is a natural constant.
And secondly, comparing the workpiece adjustment demand coefficient with a preset adjustment demand coefficient threshold value, if the workpiece adjustment demand coefficient is smaller than the preset adjustment demand coefficient threshold value, indicating that the workpiece does not need to be adjusted, and if the workpiece adjustment demand coefficient is larger than or equal to the preset adjustment demand coefficient threshold value, controlling the workpiece adjustment module to adjust the workpiece.
Preferably, the specific analysis process of the workpiece adjustment module is as follows: first, the size conformity of the workpiece is readBy the formulaObtaining the dimension conformity difference of the workpieceWhereinAnd (3) representing the set size compliance reference value, comparing the size compliance reference value with a preset size compliance difference value threshold, executing a second step if the size compliance difference value of the workpiece is smaller than the preset size compliance difference value threshold, and sending a notification of workpiece replacement to the system if the size compliance difference value of the workpiece is larger than or equal to the preset size compliance difference value threshold.
And secondly, reading the position coincidence degree of the workpiece, carrying out the same analysis to obtain the position coincidence degree difference value of the workpiece according to a method for analyzing the size coincidence degree difference value of the workpiece, comparing the position coincidence degree difference value with a preset position coincidence degree difference value threshold, executing the third step if the position coincidence degree difference value of the workpiece is smaller than the preset position coincidence degree difference value threshold, and sending a notification for adjusting the position of the workpiece to the system if the position coincidence degree difference value of the workpiece is larger than or equal to the preset position coincidence degree difference value threshold.
And thirdly, reading the clamping force of the workpiece, obtaining a clamping force difference value of the workpiece by using the clamping force difference value and the standard clamping force difference value of the workpiece, and adjusting the workpiece clamping device according to the clamping force difference value of the workpiece.
Preferably, a specific analysis process of the machining precision coincidence degree of the first part of the workpiece is as follows: the first step, a laser scanner is utilized to scan a workpiece processing requirement drawing, a digital image is generated, a workpiece processing requirement model is constructed, the workpiece processing requirement model is divided according to set workpiece parts and is marked as a model of each part of the workpiece, a processing sequence is manually selected according to the model of each part of the workpiece and is marked as a workpiece processing path, and each part of the workpiece is sequentially marked as a first part, a second part and a third part … … according to the workpiece processing pathThe part of the material is provided with a plurality of holes,Indicating the number of locations on the workpiece.
Step two, processing the first part of the workpiece, scanning the first part of the workpiece through a 3D scanning instrument after the processing is finished, constructing a 3D model, marking the model as a first part processing model, and marking the volume asSimultaneously, a first part model is selected from all part models of the workpiece, and the volume of the first part model is extracted and recorded asSimultaneously, the first part processing model and the first part model are overlapped and compared to obtain the volume of the overlapped part, which is recorded asBy the formulaObtaining the dimension conformity of the first part。
Thirdly, selecting a certain number of sampling points in a processing area of the first part processing model, measuring the height data of each sampling point by using a laser measuring instrument, and marking asWhereinRepresent the firstThe number of the sampling points,By the formulaObtaining the surface roughness of the first partWhereinRepresenting the number of sampling points.
Fourth, reading the volume of the first part processing modelAnd a volume for the first site standard modelBy the formulaObtaining the machining precision coincidence degree of the first part of the workpieceWhereinRepresents the set standard value of the surface roughness,The weight factors of the set size conformity and the surface roughness are respectively shown.
Preferably, the specific analysis method of the machining precision coincidence degree of each part of the workpiece comprises the following steps: reading the machining precision coincidence degree of the first part of the workpiece, if the machining precision coincidence degree of the first part of the workpiece is not 0, continuing to machine the second part of the workpiece, and obtaining the machining precision coincidence degree of the second part of the workpiece according to the method of analyzing the machining precision coincidence degree of the first part of the workpiece by the same analysis, if the machining precision coincidence degree of the second part of the workpiece is not 0, continuing to machine the third part of the workpiece … …, thereby obtaining the machining precision coincidence degree of each part of the workpiece, and recording asWhereinRepresenting the first of the workpiecesThe number of the parts of the medicine is that,If the machining precision of a certain part of the workpiece is 0, the workpiece fails to be machined, the next part is not needed to be machined, and a notification of workpiece replacement is sent to the system.
Preferably, the specific analysis process of the secondary processing analysis module is as follows: the method comprises the steps of firstly, reading the machining precision coincidence degree of each part of a workpiece, respectively comparing the machining precision coincidence degree of each part of the workpiece with a preset machining precision coincidence degree threshold value, if the machining precision coincidence degree of a certain part of the workpiece is larger than or equal to the preset machining precision coincidence degree threshold value, indicating that the machining of the part of the workpiece is qualified, and if the machining precision coincidence degree of a certain part of the workpiece is smaller than the preset machining precision coincidence degree threshold value, indicating that the machining of the part of the workpiece is unqualified, and carrying out secondary machining.
Secondly, counting all unqualified parts of the workpiece, scanning all unqualified parts of the workpiece through a 3D scanning instrument, constructing a 3D model, marking the model as a processing model of each unqualified part, and marking the volume asWhereinRepresenting the first of the workpiecesThe number of the unqualified part is calculated,Simultaneously extracting the volume of each part model of the workpiece, screening the volume of the workpiece part model corresponding to each unqualified part of the workpiece from the volume, and marking the volume asBy the formulaObtaining the secondary processing compensation quantity of each unqualified part of the workpieceAnd performing secondary processing on each unqualified part of the workpiece.
Preferably, the specific analysis process of the standard evaluation index analysis module is as follows: the first step, analyzing the workpiece parts after secondary processing according to the method for analyzing the processing precision coincidence degree of the workpiece parts, obtaining the processing precision coincidence degree of the workpiece parts after secondary processing, and recording asSubstituting it into formulaObtaining standard evaluation index of the workpieceWhereinIndicating the set processing precision accords with the standard value,Indicating the number of locations on the workpiece.
And secondly, comparing the standard evaluation index of the workpiece with a preset standard evaluation index range corresponding to each processing evaluation grade, and matching to obtain the processing evaluation grade of the workpiece.
Preferably, the invention provides a machine tool operation and processing control method based on the Internet of things, which comprises the following specific steps: s1, workpiece fixing detection analysis: and detecting the position conformity, the size conformity and the clamping force of the workpiece, and analyzing to obtain the workpiece adjustment demand coefficient.
S2, workpiece adjustment: judging whether the workpiece needs to be adjusted or not according to the workpiece adjustment requirement coefficient, and classifying and adjusting the workpiece according to the position conformity, the size conformity and the clamping force of the workpiece.
S3, workpiece processing planning: the method is used for obtaining a workpiece processing requirement model through drawing scanning, and further selecting a processing path according to a workpiece part to be processed.
S4, detecting and analyzing processing parameters: and detecting the processing parameters of the first part of the workpiece in real time according to the processing path of the workpiece, analyzing to obtain the processing precision coincidence degree of the first part of the workpiece, and further processing each part of the workpiece in sequence to obtain the processing precision coincidence degree of each part of the workpiece, wherein the processing parameters comprise the size coincidence degree and the surface roughness.
S5, secondary processing analysis: and comparing the machining precision coincidence degree of each part of the workpiece with a preset machining precision coincidence degree threshold value to obtain coincidence degree deviation of each part of the workpiece, and further judging whether the workpiece needs to be subjected to secondary machining or not, so as to obtain secondary machining compensation quantity of each part of the workpiece.
S6, standard evaluation index analysis: and analyzing the machining precision coincidence degree of each part of the workpiece to obtain a standard evaluation index of the workpiece, and comparing the standard evaluation index with a preset standard evaluation index range corresponding to each machining evaluation grade, thereby obtaining the machining evaluation grade of the workpiece.
Compared with the prior art, the invention has the following beneficial effects: 1. according to the invention, the workpiece adjustment demand coefficient is obtained through analysis according to the position conformity, the size conformity and the clamping force of the workpiece, so that whether the workpiece needs to be adjusted is judged, and the workpiece is classified and adjusted according to the workpiece adjustment demand coefficient, so that whether the workpiece needs to be adjusted can be more accurately judged, the processing parameters are adjusted, the processing precision is improved, and the processed part is ensured to meet the specification requirement.
2. According to the invention, each part of the workpiece is sequentially processed according to the processing path of the workpiece, the processing precision conformity of each part of the workpiece is obtained, the subsequent processing can be adjusted according to the processing result of the previous part of the workpiece, the precision condition in the processing process can be monitored in time, the problem of the subsequent processing caused by inaccurate processing of the previous part is avoided, the processing waste is reduced, and the production cost is reduced.
3. According to the invention, the machining precision coincidence degree of each part of the workpiece is compared with the preset machining precision coincidence degree threshold value, so that the coincidence degree deviation of each part of the workpiece is obtained, and whether the workpiece needs to be subjected to secondary machining is further judged, so that the secondary machining compensation quantity of each part of the workpiece is obtained, the addition parameters can be timely adjusted, the machining defects can be repaired, the production quantity of unqualified products can be effectively reduced, and the production efficiency can be improved.
4. According to the method, the standard evaluation index of the workpiece is obtained according to the machining precision coincidence degree analysis of each part of the workpiece, and is compared with the standard evaluation index range corresponding to each preset machining evaluation grade, so that the machining evaluation grade of the workpiece is obtained, the machining quality of the workpiece can be effectively evaluated, and the method has objectivity and accuracy.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed for the description of the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a system module connection diagram of a machine tool operation and processing control system based on the internet of things.
Fig. 2 is a flowchart of a machine tool operation and machining control method based on the internet of things.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, a machine tool operation processing control system based on the internet of things comprises a workpiece fixing detection module, a workpiece fixing analysis module, a workpiece adjustment module, a workpiece processing planning module, a processing parameter detection analysis module, a secondary processing analysis module, a standard evaluation index analysis module and a management database.
The management database is connected with the workpiece fixing analysis module, the workpiece adjustment module, the workpiece machining planning module, the machining parameter detection analysis module, the secondary machining analysis module and the standard evaluation index analysis module, and the workpiece fixing analysis module is connected with the workpiece fixing detection module and the workpiece adjustment module and connected with the secondary machining analysis module.
And the workpiece fixing detection module is used for detecting the position conformity, the size conformity and the clamping force of the workpiece.
The specific analysis process of the workpiece fixing detection module is as follows: the method comprises the steps of firstly, scanning a workpiece to be processed through a laser scanner to obtain three-dimensional point cloud data of the surface of the workpiece, reconstructing a three-dimensional model of the workpiece according to the three-dimensional point cloud data of the surface of the workpiece, marking the three-dimensional model as a workpiece three-dimensional model, simultaneously taking a plurality of position points on the surface of the workpiece according to a set distance, reading three-dimensional coordinates of each position point of the three-dimensional model of the workpiece, and marking the three-dimensional coordinates asWhereinRepresent the firstThe number of the point of the position,Reading the design coordinates of each position point of the workpiece from the management databaseSubstituting it into formulaObtaining the position conformity of the workpiece, which is recorded asWhereinRepresenting the number of location points; the position deviation of the workpiece can be found in time by calculating the deviation coordinates and the position conformity, and the position deviation is regulated and corrected, so that the accuracy of the workpiece in the machining process is ensured.
Reading a workpiece standard model from a management database, superposing the workpiece standard model and the workpiece three-dimensional model to obtain a workpiece three-dimensional model and an overlapped part of the workpiece standard model, extracting the volume of the overlapped part, comparing the volume of the overlapped part with the volume of the workpiece standard model to obtain the size conformity of the workpiece, and recording as; The method realizes the accurate measurement and comparison of the size of the workpiece, and is favorable for detecting whether the workpiece meets the design size requirement in the processing process, thereby controlling the size precision of the workpiece.
Third, the clamping force when the workpiece is clamped is detected by a force sensor arranged on the clamping device and is recorded as; The clamping device is beneficial to ensuring that the workpiece obtains proper clamping force in the processing process, and avoiding the situation that the workpiece is shifted, deformed or damaged due to insufficient or overlarge clamping force.
And the workpiece fixing analysis module is used for analyzing and obtaining a workpiece adjustment demand coefficient according to the position conformity, the size conformity and the clamping force of the workpiece so as to judge whether the workpiece needs to be adjusted.
The specific analysis process of the workpiece fixing analysis module is as follows: the first step, the position coincidence degree of the workpiece is respectively readCompliance of dimensionsClamping forceBy the formulaObtaining the workpiece adjustment demand coefficientWhereinIndicating the set standard clamping force to be applied,Respectively representing the weight factors of the set position conformity, the size conformity and the clamping force,Is a natural constant; the adjustment requirement in the workpiece processing process is quantized, various factors are comprehensively considered, the production flow is optimized, and the production efficiency and the product quality are improved.
In one embodiment of the present invention, in one embodiment,It may be set to 0.4,It may be set to 0.4,The position conformity degree can be set to 0.2, because the position conformity degree refers to the precision of the relative positions among all parts of a workpiece, the precision and the functionality of product assembly are affected, in the product which needs high-precision assembly, the importance of the position conformity degree is higher, the size conformity degree refers to the precision of the size and the geometric shape of all parts of the workpiece, the appearance and the performance of the product are affected, the inaccuracy of the size can lead to the fact that parts cannot be completely matched, and the performance and the stability of the product are affected, so the weight importance corresponding to the position conformity degree and the size conformity degree is higher than the clamping force.
Secondly, comparing the workpiece adjustment demand coefficient with a preset adjustment demand coefficient threshold value, if the workpiece adjustment demand coefficient is smaller than the preset adjustment demand coefficient threshold value, indicating that the workpiece does not need to be adjusted, and if the workpiece adjustment demand coefficient is larger than or equal to the preset adjustment demand coefficient threshold value, controlling a workpiece adjustment module to adjust the workpiece; the method can help to quickly judge whether the workpiece needs to be adjusted, avoid errors and delays of subjective judgment, and adjust the workpiece only when the workpiece adjustment demand coefficient exceeds a threshold value, so that the production efficiency can be improved, and the adjustment cost can be saved.
And the workpiece adjusting module is used for classifying and adjusting the workpieces according to the position conformity, the size conformity and the clamping force of the workpieces.
The specific analysis process of the workpiece adjustment module is as follows: first, the size conformity of the workpiece is readBy the formulaObtaining the dimension conformity difference of the workpieceWhereinRepresenting a set size compliance reference value, comparing the size compliance reference value with a preset size compliance difference value threshold, executing a second step if the size compliance difference value of the workpiece is smaller than the preset size compliance difference value threshold, and sending a notification of workpiece replacement to the system if the size compliance difference value of the workpiece is larger than or equal to the preset size compliance difference value threshold; by comparing the size conformity difference value with a preset threshold value in real time, the quality condition of the workpiece can be monitored in real time, and once the size conformity difference value of the workpiece exceeds the preset threshold value, the system can immediately send a notification of workpiece replacement, so that unqualified products are ensured not to flow into downstream working procedures.
Secondly, reading the position coincidence degree of the workpiece, carrying out the same analysis to obtain the position coincidence degree difference value of the workpiece according to a method for analyzing the size coincidence degree difference value of the workpiece, comparing the position coincidence degree difference value with a preset position coincidence degree difference value threshold, executing a third step if the position coincidence degree difference value of the workpiece is smaller than the preset position coincidence degree difference value threshold, and sending a notification for adjusting the position of the workpiece to a system if the position coincidence degree difference value of the workpiece is larger than or equal to the preset position coincidence degree difference value threshold; the error of the workpiece position is found in time and the adjustment notice is sent, so that the error assembly and the defective products can be avoided, the rejection rate in the production process is reduced, the workpiece position conformity is ensured to be within an acceptable range, and the production efficiency and the product quality are improved.
Thirdly, reading the clamping force of the workpiece, obtaining a clamping force difference value of the workpiece by using the clamping force difference value and the standard clamping force difference value of the workpiece, and adjusting a workpiece clamping device according to the clamping force difference value of the workpiece; the proper clamping force can avoid the movement or damage of the workpiece in the processing process, reduce the risk of damaging the workpiece due to improper clamping, ensure proper fixing force and reduce the possibility of damaging the surface or the structure of the workpiece.
The workpiece processing planning module is used for obtaining a workpiece processing requirement model through drawing scanning, and further selecting a processing path according to a workpiece part to be processed.
The processing parameter detection and analysis module is used for detecting the processing parameters of the first part of the workpiece in real time according to the processing path of the workpiece, analyzing to obtain the processing precision coincidence degree of the first part of the workpiece, and further processing each part of the workpiece in sequence to obtain the processing precision coincidence degree of each part of the workpiece, wherein the processing parameters comprise the size coincidence degree and the surface roughness.
The specific analysis process of the machining precision coincidence degree of the first part of the workpiece is as follows: the first step, a laser scanner is utilized to scan a workpiece processing requirement drawing, a digital image is generated, a workpiece processing requirement model is constructed, the workpiece processing requirement model is divided according to set workpiece parts and is marked as a model of each part of the workpiece, a processing sequence is manually selected according to the model of each part of the workpiece and is marked as a workpiece processing path, and each part of the workpiece is sequentially marked as a first part, a second part and a third part … … according to the workpiece processing pathThe part of the material is provided with a plurality of holes,Representing the number of parts of the workpiece; the workpiece processing requirement model is divided according to the set positions, and the processing sequence is manually selected, so that the accurate planning of the workpiece processing path can be realized, the processing sequence and the processing process can be better controlled through the fractional position processing, and the processing efficiency and the processing quality are improved.
Step two, processing the first part of the workpiece, scanning the first part of the workpiece through a 3D scanning instrument after the processing is finished, constructing a 3D model, marking the model as a first part processing model, and marking the volume asSimultaneously, a first part model is selected from all part models of the workpiece, and the volume of the first part model is extracted and recorded asSimultaneously, the first part processing model and the first part model are overlapped and compared to obtain the volume of the overlapped part, which is recorded asBy the formulaObtaining the dimension conformity of the first part; The method is beneficial to finding out machining errors or deviations in time, ensures that the dimension conformity of the workpiece is within a standard range, avoids waste caused by the dimension deviations, reduces cost waste, improves the dimension conformity, can reduce the product reworking rate, improves the production efficiency and reduces the machining cost.
Thirdly, selecting a certain number of sampling points in a processing area of the first part processing model, measuring the height data of each sampling point by using a laser measuring instrument, and marking asWhereinRepresent the firstThe number of the sampling points,By the formulaObtaining the surface roughness of the first partWhereinRepresenting the number of sampling points; by calculating the height data and the surface roughness value of the sampling points, the real-time monitoring of the surface quality can be realized, possible problems in the processing process can be found in time, the processing parameters can be adjusted in time, and the quality of the surface of the workpiece is ensured to meet the requirements.
Fourth, reading the volume of the first part processing modelAnd a volume for the first site standard modelBy the formulaObtaining the machining precision coincidence degree of the first part of the workpieceWhereinRepresents the set standard value of the surface roughness,Weight factors respectively representing the set size conformity and the surface roughness; the machining precision compliance is monitored in real time, so that the machining process can be timely adjusted, and the compliance with standard requirements is ensured.
In one embodiment of the present invention, in one embodiment,It may be set to 0.7,The dimension compliance may be set to 0.3, because the dimension compliance refers to the degree of compliance between the dimensions and geometry of the workpiece and the design requirements, and in engineering manufacture, the assemblability, functionality and appearance quality of the product are directly affected, so that the weight importance corresponding to the dimension compliance is higher than the surface roughness.
The specific analysis method for the machining precision coincidence degree of each part of the workpiece comprises the following steps: reading the machining precision coincidence degree of the first part of the workpiece, if the machining precision coincidence degree of the first part of the workpiece is not 0, continuing to machine the second part of the workpiece, and obtaining the machining precision coincidence degree of the second part of the workpiece according to the method of analyzing the machining precision coincidence degree of the first part of the workpiece by the same analysis, if the machining precision coincidence degree of the second part of the workpiece is not 0, continuing to machine the third part of the workpiece … …, thereby obtaining the machining precision coincidence degree of each part of the workpiece, and recording asWhereinRepresenting the first of the workpiecesThe number of the parts of the medicine is that,If the machining precision of a certain part of the workpiece is 0, the workpiece fails to be machined, the next part is not needed to be machined, and a workpiece replacement notification is sent to the system; by analyzing the machining precision coincidence degree of each part, the possible problems in the machining process of the workpiece can be monitored in real time, and once the machining precision of a certain part is found to be inconsistent, the machining can be stopped in time and corresponding measures can be taken, so that the waste of resources and time is avoided.
The secondary processing analysis module is used for comparing the processing precision coincidence degree of each part of the workpiece with a preset processing precision coincidence degree threshold value to obtain coincidence degree deviation of each part of the workpiece, and further judging whether the workpiece needs secondary processing or not, so that secondary processing compensation quantity of each part of the workpiece is obtained.
The specific analysis process of the secondary processing analysis module is as follows: the method comprises the steps of firstly, reading the machining precision coincidence degree of each part of a workpiece, respectively comparing the machining precision coincidence degree of each part of the workpiece with a preset machining precision coincidence degree threshold value, if the machining precision coincidence degree of a certain part of the workpiece is larger than or equal to the preset machining precision coincidence degree threshold value, indicating that the machining of the part of the workpiece is qualified, and if the machining precision coincidence degree of a certain part of the workpiece is smaller than the preset machining precision coincidence degree threshold value, indicating that the machining of the part of the workpiece is unqualified, and carrying out secondary machining; once the machining precision of a certain part of the workpiece is found to be inconsistent, the part is immediately subjected to secondary machining, so that unqualified products are prevented from flowing into a downstream production link, the defective rate is effectively reduced, and the product quality is improved.
Secondly, counting all unqualified parts of the workpiece, scanning all unqualified parts of the workpiece through a 3D scanning instrument, constructing a 3D model, marking the model as a processing model of each unqualified part, and marking the volume asWhereinRepresenting the first of the workpiecesThe number of the unqualified part is calculated,Simultaneously extracting the volume of each part model of the workpiece, screening the volume of the workpiece part model corresponding to each unqualified part of the workpiece from the volume, and marking the volume asBy the formulaObtaining the secondary processing compensation quantity of each unqualified part of the workpiecePerforming secondary processing on each unqualified part of the workpiece; the calculated secondary machining compensation quantity can accurately guide the secondary machining process through 3D scanning and model construction, the generation of unqualified products is reduced, blind machining and waste are avoided, the rejection rate is reduced, and cost and resources are saved.
The standard evaluation index analysis module is used for analyzing and obtaining the standard evaluation index of the workpiece according to the machining precision coincidence degree of each part of the workpiece, and comparing the standard evaluation index with the preset standard evaluation index range corresponding to each machining evaluation grade, so that the machining evaluation grade of the workpiece is obtained.
The specific analysis process of the standard evaluation index analysis module is as follows: the first step, analyzing the workpiece parts after secondary processing according to the method for analyzing the processing precision coincidence degree of the workpiece parts, obtaining the processing precision coincidence degree of the workpiece parts after secondary processing, and recording asSubstituting it into formulaObtaining standard evaluation index of the workpieceWhereinIndicating the set processing precision accords with the standard value,Representing the number of parts of the workpiece; the standard evaluation index reflects the processing precision coincidence condition of each part of the product, is favorable for establishing an effective quality control mechanism, and can adjust the processing technology in time according to the result of the evaluation index, control the processing process and improve the quality stability of the product.
Secondly, comparing the standard evaluation index of the workpiece with a preset standard evaluation index range corresponding to each processing evaluation grade, and matching to obtain the processing evaluation grade of the workpiece; according to the processing evaluation grade of the workpiece, quality problems and improvement spaces existing in products can be clearly identified, products with different grades represent different processing quality levels, the problem can be found out, and technological processes and control measures can be improved in a targeted manner.
And the management database is used for storing the design coordinates of each position point of the workpiece and the standard model of the workpiece.
Referring to fig. 2, in addition, the invention provides a machine tool operation and machining control method based on the internet of things, which specifically comprises the following steps: s1, workpiece fixing detection analysis: and detecting the position conformity, the size conformity and the clamping force of the workpiece, and analyzing to obtain the workpiece adjustment demand coefficient.
S2, workpiece adjustment: judging whether the workpiece needs to be adjusted or not according to the workpiece adjustment requirement coefficient, and classifying and adjusting the workpiece according to the position conformity, the size conformity and the clamping force of the workpiece.
S3, workpiece processing planning: the method is used for obtaining a workpiece processing requirement model through drawing scanning, and further selecting a processing path according to a workpiece part to be processed.
S4, detecting and analyzing processing parameters: and detecting the processing parameters of the first part of the workpiece in real time according to the processing path of the workpiece, analyzing to obtain the processing precision coincidence degree of the first part of the workpiece, and further processing each part of the workpiece in sequence to obtain the processing precision coincidence degree of each part of the workpiece, wherein the processing parameters comprise the size coincidence degree and the surface roughness.
S5, secondary processing analysis: and comparing the machining precision coincidence degree of each part of the workpiece with a preset machining precision coincidence degree threshold value to obtain coincidence degree deviation of each part of the workpiece, and further judging whether the workpiece needs to be subjected to secondary machining or not, so as to obtain secondary machining compensation quantity of each part of the workpiece.
S6, standard evaluation index analysis: and analyzing the machining precision coincidence degree of each part of the workpiece to obtain a standard evaluation index of the workpiece, and comparing the standard evaluation index with a preset standard evaluation index range corresponding to each machining evaluation grade, thereby obtaining the machining evaluation grade of the workpiece.
The system obtains a workpiece adjustment demand coefficient through the position conformity, the size conformity and the clamping force analysis of the workpiece, further carries out classification adjustment on the workpiece, detects the processing parameters of each part of the workpiece according to a processing path to obtain the processing precision conformity of each part of the workpiece, compares the processing precision conformity with a preset processing precision conformity threshold value to obtain the conformity deviation of each part of the workpiece, further judges whether the workpiece needs to be subjected to secondary processing and obtains the secondary processing compensation quantity of each part of the workpiece, finally obtains the standard evaluation index of the workpiece according to the processing precision conformity analysis of each part of the workpiece after the secondary processing, thereby obtaining the processing evaluation grade of the workpiece, being capable of more intuitively knowing the processing quality condition of the workpiece, being convenient for timely adjusting and optimizing the processing flow, and further improving the overall processing efficiency and quality.
While embodiments of the present invention have been shown and described above, it should be understood that the above embodiments are illustrative and not to be construed as limiting the invention, and that variations, modifications, alternatives, and variations may be made to the above embodiments by one of ordinary skill in the art within the scope of the invention, which is also intended to be covered by the present invention.
Claims (5)
1. The machine tool operation and processing control system based on the Internet of things is characterized by comprising the following modules:
The workpiece fixing and detecting module is used for detecting the position conformity, the size conformity and the clamping force of the workpiece;
the workpiece fixing analysis module is used for analyzing the position conformity, the size conformity and the clamping force of the workpiece to obtain a workpiece adjustment demand coefficient so as to judge whether the workpiece needs to be adjusted or not;
the workpiece adjusting module is used for classifying and adjusting the workpieces according to the position conformity, the size conformity and the clamping force of the workpieces;
The workpiece processing planning module is used for obtaining a workpiece processing requirement model through drawing scanning, and further selecting a processing path according to a workpiece part to be processed;
The processing parameter detection analysis module is used for detecting processing parameters of a first part of the workpiece in real time according to a processing path of the workpiece, analyzing to obtain the processing precision coincidence degree of the first part of the workpiece, and further processing each part of the workpiece in sequence to obtain the processing precision coincidence degree of each part of the workpiece, wherein the processing parameters comprise the size coincidence degree and the surface roughness;
the secondary processing analysis module is used for comparing the processing precision coincidence degree of each part of the workpiece with a preset processing precision coincidence degree threshold value to obtain coincidence degree deviation of each part of the workpiece, and further judging whether the workpiece needs secondary processing or not, so as to obtain secondary processing compensation quantity of each part of the workpiece;
The standard evaluation index analysis module is used for analyzing the machining precision coincidence degree of each part of the workpiece to obtain the standard evaluation index of the workpiece, and comparing the standard evaluation index with the preset standard evaluation index range corresponding to each machining evaluation grade to obtain the machining evaluation grade of the workpiece;
The management database is used for storing design coordinates of all the position points of the workpiece and a workpiece standard model;
The specific analysis process of the workpiece fixing detection module is as follows:
The method comprises the steps of firstly, scanning a workpiece to be processed through a laser scanner to obtain three-dimensional point cloud data of the surface of the workpiece, reconstructing a three-dimensional model of the workpiece according to the three-dimensional point cloud data of the surface of the workpiece, marking the three-dimensional model as a workpiece three-dimensional model, simultaneously taking a plurality of position points on the surface of the workpiece according to a set distance, reading three-dimensional coordinates of each position point of the three-dimensional model of the workpiece, and marking the three-dimensional coordinates as Wherein/>Represents the/>Number of individual position points,/>Reading design coordinates/>, of each position point of a workpiece, from a management databaseSubstituting it into the formula/>Obtaining the position conformity of the workpiece, which is recorded as/>Wherein/>Representing the number of location points;
Reading a workpiece standard model from a management database, superposing the workpiece standard model and the workpiece three-dimensional model to obtain a workpiece three-dimensional model and an overlapped part of the workpiece standard model, extracting the volume of the overlapped part, comparing the volume of the overlapped part with the volume of the workpiece standard model to obtain the size conformity of the workpiece, and recording as ；
Third, the clamping force when the workpiece is clamped is detected by a force sensor arranged on the clamping device and is recorded as；
The specific analysis process of the workpiece fixing analysis module is as follows:
The first step, the position coincidence degree of the workpiece is respectively read Size compliance/>Clamping force/>By the formulaObtaining the workpiece adjustment demand coefficient/>Wherein/>Representing the set standard clamping force,/>Weight factors respectively representing set position conformity, size conformity and clamping force,/>Is a natural constant;
Secondly, comparing the workpiece adjustment demand coefficient with a preset adjustment demand coefficient threshold value, if the workpiece adjustment demand coefficient is smaller than the preset adjustment demand coefficient threshold value, indicating that the workpiece does not need to be adjusted, and if the workpiece adjustment demand coefficient is larger than or equal to the preset adjustment demand coefficient threshold value, controlling a workpiece adjustment module to adjust the workpiece;
The specific analysis process of the workpiece adjustment module is as follows:
first, the size conformity of the workpiece is read By the formula/>Obtaining the dimension conformity difference value/>, of the workpieceWherein/>Representing a set size compliance reference value, comparing the size compliance reference value with a preset size compliance difference value threshold, executing a second step if the size compliance difference value of the workpiece is smaller than the preset size compliance difference value threshold, and sending a notification of workpiece replacement to the system if the size compliance difference value of the workpiece is larger than or equal to the preset size compliance difference value threshold;
Secondly, reading the position coincidence degree of the workpiece, carrying out the same analysis to obtain the position coincidence degree difference value of the workpiece according to a method for analyzing the size coincidence degree difference value of the workpiece, comparing the position coincidence degree difference value with a preset position coincidence degree difference value threshold, executing a third step if the position coincidence degree difference value of the workpiece is smaller than the preset position coincidence degree difference value threshold, and sending a notification for adjusting the position of the workpiece to a system if the position coincidence degree difference value of the workpiece is larger than or equal to the preset position coincidence degree difference value threshold;
Thirdly, reading the clamping force of the workpiece, obtaining a clamping force difference value of the workpiece by using the clamping force difference value and the standard clamping force difference value of the workpiece, and adjusting a workpiece clamping device according to the clamping force difference value of the workpiece;
The specific analysis process of the standard evaluation index analysis module is as follows:
The first step, analyzing the workpiece parts after secondary processing according to the method for analyzing the processing precision coincidence degree of the workpiece parts, obtaining the processing precision coincidence degree of the workpiece parts after secondary processing, and recording as Substituting it into formulaObtaining the standard evaluation index/>, of the workpieceWherein/>Representing the set machining precision conformity standard value,/>Representing the number of parts of the workpiece;
and secondly, comparing the standard evaluation index of the workpiece with a preset standard evaluation index range corresponding to each processing evaluation grade, and matching to obtain the processing evaluation grade of the workpiece.
2. The machine tool operation processing control system based on the internet of things according to claim 1, wherein the specific analysis process of the machining precision coincidence degree of the first part of the workpiece is as follows:
The first step, a laser scanner is utilized to scan a workpiece processing requirement drawing, a digital image is generated, a workpiece processing requirement model is constructed, the workpiece processing requirement model is divided according to set workpiece parts and is marked as a model of each part of the workpiece, a processing sequence is manually selected according to the model of each part of the workpiece and is marked as a workpiece processing path, and each part of the workpiece is sequentially marked as a first part, a second part and a third part … … according to the workpiece processing path Location,/>Representing the number of parts of the workpiece;
Step two, processing the first part of the workpiece, scanning the first part of the workpiece through a 3D scanning instrument after the processing is finished, constructing a 3D model, marking the model as a first part processing model, and marking the volume as Simultaneously, a first part model is selected from all part models of the workpiece, and the volume of the first part model is extracted and recorded as/>Simultaneously, the first part processing model and the first part model are overlapped and compared to obtain the volume of the overlapped part, and the volume is recorded as/>By the formula/>Obtaining the dimension coincidence degree/>, of the first part；
Thirdly, selecting a certain number of sampling points in a processing area of the first part processing model, measuring the height data of each sampling point by using a laser measuring instrument, and marking asWherein/>Represents the/>Number of sample points,/>By the formula/>Obtaining the surface roughness of the first part/>Wherein/>Representing the number of sampling points;
fourth, reading the volume of the first part processing model And is the volume/>, of the first site standard modelBy the formulaObtaining the machining precision coincidence degree/>, of the first part of the workpieceWhereinRepresenting the set standard value of the surface roughness,/>The weight factors of the set size conformity and the surface roughness are respectively shown.
3. The machine tool operation processing control system based on the internet of things according to claim 2, wherein the specific analysis method of the processing precision coincidence degree of each part of the workpiece is as follows:
reading the machining precision coincidence degree of the first part of the workpiece, if the machining precision coincidence degree of the first part of the workpiece is not 0, continuing to machine the second part of the workpiece, and obtaining the machining precision coincidence degree of the second part of the workpiece according to the method of analyzing the machining precision coincidence degree of the first part of the workpiece by the same analysis, if the machining precision coincidence degree of the second part of the workpiece is not 0, continuing to machine the third part of the workpiece … …, thereby obtaining the machining precision coincidence degree of each part of the workpiece, and recording as Wherein/>Representing the work piece (s)/>Number of individual parts,/>If the machining precision of a certain part of the workpiece is 0, the workpiece fails to be machined, the next part is not needed to be machined, and a notification of workpiece replacement is sent to the system.
4. The machine tool operation processing control system based on the internet of things according to claim 3, wherein the specific analysis process of the secondary processing analysis module is as follows:
The method comprises the steps of firstly, reading the machining precision coincidence degree of each part of a workpiece, respectively comparing the machining precision coincidence degree of each part of the workpiece with a preset machining precision coincidence degree threshold value, if the machining precision coincidence degree of a certain part of the workpiece is larger than or equal to the preset machining precision coincidence degree threshold value, indicating that the machining of the part of the workpiece is qualified, and if the machining precision coincidence degree of a certain part of the workpiece is smaller than the preset machining precision coincidence degree threshold value, indicating that the machining of the part of the workpiece is unqualified, and carrying out secondary machining;
secondly, counting all unqualified parts of the workpiece, scanning all unqualified parts of the workpiece through a 3D scanning instrument, constructing a 3D model, marking the model as a processing model of each unqualified part, and marking the volume as Wherein/>Representing the work piece (s)/>Number of unqualified part,/>Simultaneously extracting the volume of each part model of the workpiece, screening the volume of the workpiece part model corresponding to each unqualified part of the workpiece from the volume, and marking the volume as/>By the formula/>Obtaining the secondary processing compensation quantity/>, of each unqualified part of the workpieceAnd performing secondary processing on each unqualified part of the workpiece.
5. The machine tool operation processing control method based on the internet of things, which is executed by the machine tool operation processing control system according to claim 1, is characterized in that the processing control method comprises the following specific steps:
S1, workpiece fixing detection analysis: detecting the position conformity, the size conformity and the clamping force of the workpiece, and analyzing to obtain a workpiece adjustment demand coefficient;
S2, workpiece adjustment: judging whether the workpiece needs to be adjusted or not according to the workpiece adjustment requirement coefficient, and classifying and adjusting the workpiece according to the position conformity, the size conformity and the clamping force of the workpiece;
S3, workpiece processing planning: the processing path selection method is used for obtaining a workpiece processing requirement model through drawing scanning, and further selecting a processing path according to a workpiece part to be processed;
S4, detecting and analyzing processing parameters: detecting processing parameters of a first part of the workpiece in real time according to a processing path of the workpiece, analyzing to obtain the processing precision coincidence degree of the first part of the workpiece, and further processing each part of the workpiece in sequence to obtain the processing precision coincidence degree of each part of the workpiece, wherein the processing parameters comprise the size coincidence degree and the surface roughness;
S5, secondary processing analysis: comparing the machining precision coincidence degree of each part of the workpiece with a preset machining precision coincidence degree threshold value to obtain coincidence degree deviation of each part of the workpiece, and further judging whether the workpiece needs to be subjected to secondary machining or not, so as to obtain secondary machining compensation quantity of each part of the workpiece;
S6, standard evaluation index analysis: and analyzing the machining precision coincidence degree of each part of the workpiece to obtain a standard evaluation index of the workpiece, and comparing the standard evaluation index with a preset standard evaluation index range corresponding to each machining evaluation grade, thereby obtaining the machining evaluation grade of the workpiece.
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