CN1593849A - Grinding machine data acquisition and failure diagnosis apparatus based on network - Google Patents
Grinding machine data acquisition and failure diagnosis apparatus based on network Download PDFInfo
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- CN1593849A CN1593849A CNA2004100414126A CN200410041412A CN1593849A CN 1593849 A CN1593849 A CN 1593849A CN A2004100414126 A CNA2004100414126 A CN A2004100414126A CN 200410041412 A CN200410041412 A CN 200410041412A CN 1593849 A CN1593849 A CN 1593849A
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Abstract
The invention belongs to field of mechanic and meter. Set vibration sensor, noise sensor and temperature sensor on the suitable position, get messages from these sensor and connect the message to this invention, we can judge the machine property and supply distance service and diagnosing by connecting to the net computer through Ethernet. It also can link net to the computer that has only opening, adjust diagnosing arithmetic and corresponding judgment on the net, so as to learn constantly and improve the diagnosing quality. The invention has small bulk, and needs little cost. It is simple to use it, only needing 24V direct-current. It can be used as option of the grinding table to improve precision, pertinence, and speed of mending the table. The distance service cuts down the cost and improves the efficiency.
Description
Technical field
The invention belongs to machinery and instrument field, be specifically related to a kind of grinding machine data acquisition and trouble-shooter.
Background technology
Grinding machine particularly numerically control grinder is the modern precision electromechanical equipment that integrates machinery, electronics, hydraulic pressure, possesses skills intensive and the knowledge intensive characteristics.Structurally, numerically control grinder generally is made up of digital control system, electrical system, hydraulic system, headstock, grinding carriage, lathe bed, workbench, tailstock and other accessory.On performance, have that automatic grinding circulation, emery wheel are revised automatically, technological parameter online modification and functions such as diagnosing interior faults, warning.Digital control system and PLC controller can but can not be judged automatically for many faults such as mechanical, electric because the fault that causes of controller and part electrical system is reported to the police, need manually be diagnosed and safeguard.
Grinding machine is as a kind of precise machining equipment, and its automaticity improves day by day, often all is the key equipment in the enterprise.In actual production; the working environment of grinding machine is complicated and changeable; operating position has nothing in common with each other; for the maintenance of lathe and the finishing of emery wheel; generally be rule of thumb when the official hour node arrives, carry out the maintenance of lathe or the finishing of emery wheel, this timing node is general to adopt conservative algorithm; this causes the loss of shutdown maintenance for the good lathe of operating mode, also can only be to correction maintenance for the lathe that breaks down.Along with the increase of the complexity of the development of high-speed grinding and control system, the uncertain of numerically control grinder failure cause obviously increases.And the maintenance of this kind equipment needs the professional technique attendant just can carry out.Nowadays, most of producers adopt to send the expert engineer to solve the on-the-spot problem that takes place to the measure of field diagnostic and reparation.This is for lathe manufacturer and lathe applying unit, and on the one hand, this has influenced the normal manufacturing schedule of both sides, on the other hand, has increased the maintenance cost of equipment again.For some simple troubleshooting, the cost of this processing mode is very high especially.
Compare with other lathes, the characteristics of grinding machine fault diagnosis are as follows:
1, reason complexity.The grinding machine complex structure had both comprised complicated electric control system, Hydraulic Power Transmission System, comprised the various matching mechanisms of mechanism's exquisiteness again.Therefore, same failure symptom may relate to different systems or mechanism, simultaneously, and when same system or mechanism are impaired, by producing different failure symptoms.This has just increased the complexity of fault diagnosis reasoning.
2, detection is comprehensive.In numerically control grinder, the master control system that adopts generally all contains basic fault diagnosis functions at present.But this function mainly is the simple diagnosis that is used for directly linking to each other, having with control system the element fault of measuring feedback, and promptly this functional adaptation scope is limited.In this complex device of numerically control grinder, exist the fault that a large amount of internal control systems can't be diagnosed.For example main shaft bearing wearing and tearing, bistrique are crossed the oscillation phenomenon of the different spectral that reasons such as wearing and tearing, bistrique imbalance, main shaft bearing and axle journal off-centre, oil whip cause and will be analyzed and diagnose by means of the sensor measurement technology of lathe periphery.
3, knowledge popularity.Numerically control grinder is advanced electromechanical integration precise machining equipment.Relate to many-sided application technologies such as Computer Control Technology, mechanics of communication, hydraulic technique, mechanical transmissioning technology.This just requires to have multi-field comprehensive knowledge and experience fault diagnosis person (or system), so that phenomenon of the failure is carried out deep analysis, thereby guarantees the accuracy of diagnostic result.
4, loss seriousness.Generally speaking, the finishing step that numerically control grinder is arranged in before the finished part uses, and owing to reason such as costing an arm and a leg, most producers that use do not have standby equipment for grinding.In addition, the piece surface stock removal is less, process velocity fast, batch is big.This just requires grinding machine with higher working (machining) efficiency work.In case grinding machine breaks down, will cause percent defective rising, economic loss to increase.And, when situation is serious, also can cause the maintenance that stops production.The user of the equipment of giving brings serious economy loss.This just presses for the fault diagnosis of specialty and handles service.
Along with the development of information technology, remote diagnosis and service technology grow up at medical field, and the remote fault diagnosis technology also is applied in the fault diagnosis of equipment, obtain good effect.Though many digital control systems have fault diagnosis module, it can only detect the problem that exists with diagnostic control system, and can not detect and diagnose whole machine tool.The existing fault diagnostic equipment is only gathered and is handled general signal, does not generally have the function of teledata exchange and diagnosis.So developing based on network grinding machine data acquisition and trouble-shooter has very important significance.
Summary of the invention
The object of the present invention is to provide a kind of based on network grinding machine data acquisition and trouble-shooter, can to grinding machine particularly numerically control grinder carry out on-site data gathering, operating mode judgement, fault diagnosis and remote service.It is by the vibration to lathe, temperature, noise, spindle motor current, the project of positional precision and sound rigidity detects, and the data communication of combination and machine tool control system, working condition to lathe is carried out preliminary judgement, provide information such as prompting warning, and can pass through Ethernet interface, original sampling data and Treatment Analysis result are uploaded in the computer of factory, carry out more comprehensive and analysis in depth, host computer also can will pass in this device under new diagnostic method and the diagnosis index, thus the ability that this device is had improve constantly and conform.This device also can be used as the networking conversion equipment of Digit Control Machine Tool simultaneously, changes by the serial line interface (RS232 interface) to machine tool control system, is converted to Ethernet interface, and Digit Control Machine Tool is connected in the network of factory.
According to design provided by the present invention, a kind of based on network grinding machine data acquisition and trouble-shooter are provided, comprising:
Harvester is used to gather the initial data such as noise, temperature and electric current about grinding machine;
Signal processing circuit is used for after sample from the initial data of sensor acquisition maintenance and the signal processing, and the result that initial analysis is diagnosed delivers to control device;
Control device is used for the image data and the result that obtain from signal processing circuit are sent to external network;
Display unit links to each other with control device, is used to show signal;
Press key input device links to each other with controller, can make the user carry out button input control;
The multiple power supplies plate links to each other with controller, is used to provide power supply;
External computer links to each other with controller, and the user can further analyze and handle by this computer;
The Ethernet change-over circuit is used to connect controller and EPA, thereby can carry out remote fault diagnosis, and can will pass to control device under new diagnostic method and the diagnosis index.
The present invention utilizes 32 the RISC CPU-S3C44B0X chips of Samsung company based on the ARM7TDMI kernel, make up a embedded system at grinding machine, by vibration to lathe, noise, the collection of signals such as temperature, the conditioning of employing hardware signal, the software anti-aliasing filtering, the FFT conversion, wavelet transformation and neutral net are handled and are analyzed signal, pass through time domain, frequency domain and at the criterion of grinding machine, judge the duty of lathe, guidance is accomplished machine maintenance targetedly to the maintenance of lathe, and in conjunction with the diagnosing malfunction of expert system to lathe.And can pass through Ethernet interface, original sampling data and Treatment Analysis result are uploaded in the computer of factory, carry out more comprehensive and analysis in depth, host computer also can will pass in this device under new diagnostic method and the diagnosis index, thus the ability that this device is had improve constantly and conform.This device also can be used as the networking conversion equipment of Digit Control Machine Tool simultaneously, changes by the serial line interface (RS232 interface) to machine tool control system, is converted to Ethernet interface, and Digit Control Machine Tool is connected in the network of factory.
By the data acquisition and the analytical equipment of a grinding machine of ARM chip structure, can work together with the control system of lathe, set up historical operating mode archives for lathe, lathe is diagnosed targetedly.
By network the data of gathering and the result of analyzing and diagnosing are passed, inquire about and use for the computer of networking even the online user of Internet, and can carry out the networking of numerically control grinder, can carry out the remote service and the diagnosis of lathe by this device.
The present invention is directed to the data acquisition and the diagnosis of grinding machine, adopt embedded system, 32 RISC (Reduced Instruction Set Computer) chip---arm processor.Now, characteristics such as arm processor is fast with its computing, memory space is big, power consumption is few, cost is low, function is strong, it is the embedded system of kernel that this diagnostic system is introduced with ARM7, the failure diagnosis apparatus of the grinding machine that exploitation is special-purpose.CPU is 32 the RISC CPU-S3C44B0Xs of Samsung company based on the ARM7TDMI kernel on the plate.This model C PU is a model that belongs to comparative maturity in the ARM of Samsung series of products, and is widely used.
Description of drawings
Fig. 1 is the block diagram of the system of apparatus of the present invention.
Fig. 2 is the CPU partial circuit schematic diagram of apparatus of the present invention.
Fig. 3 is the peripheral interface circuit schematic diagram of apparatus of the present invention.
Fig. 4 is the imput output circuit schematic diagram of apparatus of the present invention.
Fig. 5 is the memory circuitry schematic diagram of apparatus of the present invention.
Fig. 6 is the signal processing circuit schematic diagram of apparatus of the present invention.
Fig. 7 is the LCD circuit of apparatus of the present invention.
Fig. 8 is the A/D convertor circuit figure of apparatus of the present invention
Fig. 9 information processing logic diagram.
Figure 10 signal processing flow figure.
Figure 11 software systems block diagram.
Figure 12 fault diagnosis neural network structure chart.
The specific embodiment
1.1 the hardware index of system
The block diagram of system such as Fig. 1, system power dissipation is little, cost is low, demonstrate fully the characteristics of embedded system, but based on computer technology, hardware and software cutting, adapt to the dedicated computer system that application system is strict with function, reliability, cost, volume, power consumption.Stability is high, and it is little that plate carries all chip quantities of heat production, need not fan for cooling.System can run well in-20～70 ℃ of scopes.System has good hardware shield and disturbs and software WATCHDOG timing reset ability, to guarantee the operation stability and the anti-interference of system.Be adapted at binding use easily in the switch board of existing numerical control device.
System provides reusable, high-performance, graphical, networked software and hardware basic platform and development mode efficiently for modern TT﹠C system.Make full use of the advantage of high-level language,, make its platform possess the feature of modern embedded system for platform adds friendly man-machine interaction mode, graphic interface, network, the driving of various communication interface.CPU is 32 RISC CPU-S3C44B0X chips of Samsung company on the plate, and its numerical operation speed is fast, memory space is well-to-do.System clock frequency can be by the software setting, and high energy is to 66MHz.The index of hardware system is as follows:
● 32 RISC (Samsung S3C44B0X, ARM7TDMI CORE);
● 4M?bit?BOOT?ROM(FLASH)；
● 4M Word SDRAM, support big capacity routine data, 16/32 of data/address bus are convertible;
● 2K?bit?I2C?EEPROM；
● a LCD interface, the LM32019T LCD 320*240 of Toshiba display;
● an I2C interface; 1 passage I2S interface; 1 passage SIO interface;
● two passage RS232;
● 8 path 10 position analog quantity interfaces, the highest sample frequency reaches 100K;
● 1 Ethernet interface;
● 1 LED light, 4 buttons, 4 I/O interfaces
1.2 system specifics
System block diagram such as Fig. 1 of device, the core of system adopts 32 RISC CPU-S3C44B0X chips of Samsung company, Fig. 2 has represented the circuit theory diagrams of CPU part, Fig. 2～8th, and the circuit theory diagrams of each several part, wherein memory is divided into FLASH ROM and SDRAM.FLASH ROM is 4Mbit, is that the chip of SST39VF400A is formed by a slice model, is used for placement program and relevant parameter; SDRAM is 4M Word (a 16M byte), is made up of the chip that two models are K4S641632F, is used for store sample data and intermediate object program.By the I/O interface that the S3C44B0X chip provides itself, be extended to 4 buttons and 4 I/O interfaces, button by its function of software definition, plays a part different as user's input in different functional modules.Two RS232 serial ports are directly expanded and are obtained, Ethernet interface is realized by E5123-JHC type Ethernet/serial converter, can realize the communication speed of high bit rate 115.2K, the IP address of setting device, the communications parameter of serial ports are realized the communication based on IP, TCP, udp protocol easily.Because the interface level of the signal level range of sensor output and the AD of ARM is incompatible, must carry out preliminary treatment earlier.Fig. 6 has represented the adjustment circuit of signal, can by wire jumper realize 0～10V, 0～5V, ± 5V converts interface level 0～2.5V of the AD of ARM to.Signal is sampled by LF398 through signal after the two-stage sign-changing amplifier and is kept the back to carry out the AD conversion for ARM, sees Fig. 8.
During use, if what connect is general-purpose grinder, then only link to each other between lathe and this device by sensor, if numerically control grinder then can link to each other with this controller by the serial ports of digital control system or PLC controller, can obtain the duty of lathe so simultaneously, as data such as rotating speed, feed speeds.By collection and analysis to vibration, noise, temperature and spindle motor current etc., this device can be judged the operating mode of lathe.Field computer also can obtain data and the result that this device is gathered by network, the user carries out complicated more analysis and processing in the computer at the scene, further analyzed, and can be in database the time domain and the frequency domain transformation results of stick signal, through the accumulation of historical data and to the processing and the analysis of these data, draw more realistic judgment criteria and method, can these corrections be delivered in this device by network, the diagnostic accuracy of this device is constantly improved.Expert's computer can by Internet obtain in user's the Web website with LAN in identical information, long-range like this expert just can diagnose the lathe in strange land by Internet.
Fig. 9 has represented the information processing logic diagram.The realization of the network savvy of numerically control grinder is to link to each other with this device by the RS232 serial ports, link to each other by the Ethernet interface of this device and the network of factory then, nc program can be by network delivery in Digit Control Machine Tool like this, and Digit Control Machine Tool just can be by network and user's exchange data information.
Figure 10 has represented signal processing flow, signal carries out filtering, FFT or wavelet transformation in this device, energy on the different frequency that obtains (amplitude), with of the input (Figure 12) of these data as neutral net, adopt the form of some diagnosis subnets parallel connection, according to existing fault sample study, each subnet only is responsible for a kind of failure cause (Y of diagnosis
i).When new fault type occurring, existing subnet structure need not change and relearns like this, as long as new subnet of sign feature construction of the new fault of basis.Like this, strengthened the stability of original diagnostic network, and network opening.This structure is suitable for the numerical control device of this complexity of numerically control grinder.
Figure 11 has represented the system block diagram of software, collection, I/O interface and the communication of data is handled being placed in the different interruptions, and other tasks are placed in the backdrop procedure to be handled.Enter initialize routine after system powers on, enter the distribution of wait task then, system is provided with parameter setting, self check, field diagnostic, on-line communication and resets these five tasks.Parameter is provided with the setting that task is mainly finished systematic parameter, as information such as the corresponding relation of numbering, model, passage and the sensor of grinding machine, sample frequencys.The self check task is finished the detection to button, I/O interface, communication interface and A/D converter.Field diagnostic task start automatic diagnosis flow process, collection, processing and analysis by to signal provide judged result, break down or the trend that produces fault is arranged as judgement, provide warning, and send warning message by network.The on-line communication task can be arranged to Digit Control Machine Tool networking and remote fault diagnosis pattern, finish with network on the communication task of computer.
Claims (10)
1, a kind of based on network grinding machine data acquisition and trouble-shooter is characterized in that comprising:
Harvester is used to gather the initial data such as noise, temperature and electric current about grinding machine;
Signal processing circuit is used for after sample from the initial data of sensor acquisition maintenance and the signal processing, and the result that initial analysis is diagnosed delivers to control device;
Control device is used for the image data and the result that obtain from signal processing circuit are sent to external network;
Display unit links to each other with control device, is used to show signal;
Press key input device links to each other with controller, can make the user carry out button input control;
The multiple power supplies plate links to each other with controller, is used to provide power supply;
External computer links to each other with controller, and the user can further analyze and handle by this computer;
The Ethernet change-over circuit is used to connect controller and EPA, thereby can carry out remote fault diagnosis, and can will pass to control device under new diagnostic method and the diagnosis index.
2, grinding machine data acquisition as claimed in claim 1 and trouble-shooter is characterized in that, described control device also comprises a memory, and wherein said control device is a programmable cpu controller, and described memory is FLASH ROM and SDRAM.
3, grinding machine data acquisition as claimed in claim 1 and trouble-shooter is characterized in that, under the situation of general-purpose grinder, described harvester is a sensor, and under the situation of numerically control grinder, described harvester is digital control system or PLC controller.
4, grinding machine data acquisition as claimed in claim 1 and trouble-shooter is characterized in that, described extraneous computer can be PC or portable computer.
5, grinding machine data acquisition as claimed in claim 1 and trouble-shooter, it is characterized in that, described signal is handled and is comprised, the conditioning of employing hardware signal, software anti-aliasing filtering, FFT conversion, wavelet transformation and neutral net are handled and are analyzed signal, by time domain, frequency domain with at the criterion of grinding machine, judge the duty of lathe.
6, grinding machine data acquisition as claimed in claim 1 and trouble-shooter, it is characterized in that, utilize the programmable cpu controller to constitute the embedded system at grinding machine, this system is provided with parameter setting, self check, field diagnostic, on-line communication and resets these five kinds of mode of operations.
7, grinding machine data acquisition as claimed in claim 6 and trouble-shooter is characterized in that, under parameter is provided with pattern, carry out the setting of systematic parameter, as information such as the corresponding relation of numbering, model, passage and the sensor of grinding machine, sample frequencys.
8, grinding machine data acquisition as claimed in claim 6 and trouble-shooter is characterized in that, finish the detection to button, I/O interface, communication interface and A/D converter under Auto-Sensing Mode.
9, grinding machine data acquisition as claimed in claim 6 and trouble-shooter, it is characterized in that, at the scene under the diagnostic mode, start the automatic diagnosis flow process, collection, processing and analysis by to signal provide judged result, break down or the trend that produces fault is arranged as judgement, provide warning, and send warning message by network.
10, grinding machine data acquisition as claimed in claim 6 and trouble-shooter is characterized in that, under the on-line communication pattern, can be arranged to Digit Control Machine Tool networking and remote fault diagnosis pattern, finish with network on the communication task of computer.
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Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN100346928C (en) * | 2005-04-26 | 2007-11-07 | 上海铭华检测设备成套有限公司 | Automatic detection equipment and method by response mode between roller detection equipment and grinder |
| CN102284886A (en) * | 2011-05-11 | 2011-12-21 | 南京工业职业技术学院 | Portable intelligent installation-debugging guidance and fault diagnosis device |
| WO2012088707A1 (en) * | 2010-12-31 | 2012-07-05 | 中国科学院自动化研究所 | Intelligent detecting system and detecting method for detecting fault of device |
| CN103197603A (en) * | 2013-04-08 | 2013-07-10 | 上海维宏电子科技股份有限公司 | Data collection analyzer for numerical control system |
| CN103309318A (en) * | 2013-06-03 | 2013-09-18 | 镇江中福马机械有限公司 | Remote data monitoring system of hot mill |
| CN103692350A (en) * | 2013-11-20 | 2014-04-02 | 杭州电子科技大学 | Integrated CNC (computer numerical control) grinding machine control system with fault detection |
| CN104023914A (en) * | 2011-12-28 | 2014-09-03 | Ntn株式会社 | Processing diameter measurement device with grinder measurement malfunction assessment function |
| CN105022313A (en) * | 2014-05-07 | 2015-11-04 | 奚涛 | Multipath data acquisition control module |
| CN106406231A (en) * | 2016-06-07 | 2017-02-15 | 西安交通大学 | Machine tool spindle intelligent online monitoring and integration diagnosis system based on Internet |
| CN106485073A (en) * | 2016-10-12 | 2017-03-08 | 浙江理工大学 | A kind of grinding machine method for diagnosing faults |
| CN106842922A (en) * | 2017-01-14 | 2017-06-13 | 合肥工业大学 | A kind of NC Machining Error optimization method |
| CN109144144A (en) * | 2018-08-14 | 2019-01-04 | 无锡诚勇自动化技术有限公司 | A kind of device data acquisition system |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN100346928C (en) * | 2005-04-26 | 2007-11-07 | 上海铭华检测设备成套有限公司 | Automatic detection equipment and method by response mode between roller detection equipment and grinder |
| WO2012088707A1 (en) * | 2010-12-31 | 2012-07-05 | 中国科学院自动化研究所 | Intelligent detecting system and detecting method for detecting fault of device |
| CN103250107A (en) * | 2010-12-31 | 2013-08-14 | 中国科学院自动化研究所 | Intelligent detecting system and detecting method for detecting fault of device |
| CN102284886A (en) * | 2011-05-11 | 2011-12-21 | 南京工业职业技术学院 | Portable intelligent installation-debugging guidance and fault diagnosis device |
| CN102284886B (en) * | 2011-05-11 | 2013-01-09 | 南京工业职业技术学院 | Portable intelligent installation-debugging guidance and fault diagnosis device |
| CN104023914A (en) * | 2011-12-28 | 2014-09-03 | Ntn株式会社 | Processing diameter measurement device with grinder measurement malfunction assessment function |
| US9285200B2 (en) | 2011-12-28 | 2016-03-15 | Ntn Corporation | Processing diameter measurement device with grinder measurement malfunction assessment function |
| CN103197603A (en) * | 2013-04-08 | 2013-07-10 | 上海维宏电子科技股份有限公司 | Data collection analyzer for numerical control system |
| CN103309318A (en) * | 2013-06-03 | 2013-09-18 | 镇江中福马机械有限公司 | Remote data monitoring system of hot mill |
| CN103692350A (en) * | 2013-11-20 | 2014-04-02 | 杭州电子科技大学 | Integrated CNC (computer numerical control) grinding machine control system with fault detection |
| CN103692350B (en) * | 2013-11-20 | 2016-02-17 | 杭州电子科技大学 | The integrated numerical control Development of Grinding Machines'Control System that tape jam detects |
| CN105022313A (en) * | 2014-05-07 | 2015-11-04 | 奚涛 | Multipath data acquisition control module |
| CN106406231A (en) * | 2016-06-07 | 2017-02-15 | 西安交通大学 | Machine tool spindle intelligent online monitoring and integration diagnosis system based on Internet |
| CN106485073A (en) * | 2016-10-12 | 2017-03-08 | 浙江理工大学 | A kind of grinding machine method for diagnosing faults |
| CN106842922A (en) * | 2017-01-14 | 2017-06-13 | 合肥工业大学 | A kind of NC Machining Error optimization method |
| CN106842922B (en) * | 2017-01-14 | 2020-07-17 | 合肥工业大学 | Numerical control machining error optimization method |
| CN109144144A (en) * | 2018-08-14 | 2019-01-04 | 无锡诚勇自动化技术有限公司 | A kind of device data acquisition system |
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