CN202948288U - Sawing load detection device based on flutter characteristic of metal band saw blade - Google Patents

Abstract

The utility model relates to a sawing load detection device based on the flutter characteristic of a metal band saw blade. The device is composed of an eddy current sensor module, a signal acquisition module, a signal processing module and a human machine interface module, wherein the eddy current sensor module comprises four sets of eddy current sensors and four sets of brackets with bases, and the four sets of eddy current sensors are evenly fixed on the four sets of brackets with bases; the four sets of brackets with bases are fixed on a guide device of a metal band sawing machine and can be adjusted to enable probes of the four sets of eddy current sensors to be on the same horizontal plane and perpendicular to a saw band portion of the metal band saw blade; and a conversion plate and an acquisition card are adopted on the signal acquisition module. The device is simple in assembly with the existing band sawing machine mechanism and small in effects on actual production; and the response speed of a detection system is high, the information memory space is large, and the accuracy is high.

Description

A kind of sawing Weight detector based on the band saw for metal buffet characteristic

Technical field

The utility model relates to a kind of contactless band saw for metal sawing Weight detector, particularly a kind of sawing Weight detector based on the band saw for metal buffet characteristic.

Background technology

Band saw machine is a kind of blanking procedure major equipment, and is high with its sawing precision, saw kerf is little, has the characteristics such as energy-efficient, is widely used in the occasions such as the various metal materials of sawing and nonmetallic materials.In actual sawing processing, appearance along with complex working conditions such as the unordered variation of processing work sectional area, the sudden change of processing work material hardness, the wearing and tearing of sawtooth land, corresponding the changing of band saw for metal sawing load parameter meeting, Correlation Theory analysis both is comparatively complicated, but machining precision, the working (machining) efficiency of subsequent technique had larger impact.Therefore, need the sawing Weight detector of a kind of band sawing machine of development, high precision int, the high efficiency of studying band saw machine had very important significance.

at present, in association area not based on the sawing Weight detector of band saw machine, be CN101135899 (Granted publication CN200710009663.X as the patent No., March 5 2008 Granted publication day) a kind of precision numerically controlled machine on-line detecting system is disclosed, this system adopts point-to-multipoint wireless serial communication modes, comprise precise numerical control machine, servo-drive system, digital control system, sensor, the multichannel sensor interface circuit, single-chip microcomputer, wireless data transmission module and industrial computer, sensor is servo-actuated to be arranged on precise numerical control machine, the Single-chip Controlling sensor data acquisition, industrial computer carries out exchanges data by wireless data transmission module and single-chip microcomputer, be provided with online detection and error compensation software in industrial computer.This system can detect the work of numerical control machine situation in real time, can carry out error compensation to numerically-controlled machine to a certain extent, improves the lathe operating accuracy.But this system lacks the ability of analyzing continuously a large amount of vibrating signals, can't be applied to the working environment of complex working condition, can't carry out intelligent decision and analysis to working condition, therefore, and is not suitable for sawing load detecting requirement based on the band saw for metal buffet characteristic.be CN201010102851.9 (Granted publication CN101769785A as the patent No., July 7 2010 Granted publication day) a kind of detecting method and pick-up unit of water filling unit vibrational state are disclosed, this device involving vibrations detection module, the apparatus of load detection module, the acoustic emission detection module, the rotating speed detection module, presence detects analysis module, the pick-up unit of database management module and many signals modulation module, under normal condition, the vibration signal that the vibration detection module gathers, the acoustic emission detection module gathers acoustic emission signal, the apparatus of load detection module records the data of equipment, the sound signal that calculates modulation deposits database management module in, when equipment is carried out spot check, deposit the signal of actual acquisition in data management module, calculate the actual signal sound signal, by earphone, normal condition reference audio signal and actual motion state sound signal are monitored comparison.This device adopts multiple sensors, gathers the many places analog signals, can compare for the situation in the lathe operational process comparatively all sidedly, and the based on database signal management is processed the adaptive ability that has also improved detection system.But this installation cost is higher, and adopts acoustic signal to compare, and the subjective judgement composition is larger, is unfavorable for objective analysis.Therefore be not suitable for band saw for metal sawing load detecting.The utility model provides a kind of sawing Weight detector based on the band saw for metal buffet characteristic for the deficiency of above technology.

Summary of the invention

The purpose of this utility model is to provide a kind of contactless band saw for metal sawing to load on line detector; It is a kind of pick-up unit of the correlation principle based on bands for band buffet characteristic and sawing load; Be a kind of vibrating signal by high frequency sample strip saw blade, then carry out signal processing of flutter, feature extraction and correlativity conversion, obtain the indirect pick-up unit of sawing load characteristic; It is a kind of pick-up unit of quick reflection sawing load variations; A kind ofly can carry out the on-line measuring device that intelligent decision is estimated to each sawing operating mode.

The technical scheme that the utility model technical solution problem adopts is:

The utility model is comprised of current vortex sensor module, signal acquisition module, signal processing module, human-computer interface module; Wherein the current vortex sensor module comprises the support of quadruplet current vortex sensor and quadruplet band base.

Described current vortex sensor module, its quadruplet current vortex sensor is divided equally on the support that is fixed in quadruplet band base, the band saw dither offset amount that when being respectively used to measure band saw work, workpiece both sides sawing produces.

Described support with base is fixed on the guide piece of band saw machine, and adjustable support makes the probe of quadruplet current vortex sensor all in same level and perpendicular to band saw for metal saw band part.

The band saw dither offset amount that when described current vortex sensor is used for measuring band saw work, workpiece both sides sawing produces.

Described signal acquisition module adopts change-over panel and capture card, the current vortex sensor signal output part is connected with the analog input Wiring port of change-over panel, described change-over panel is connected by cable with described capture card, and described capture card is connected with PC PCI slot.

The band saw dither offset amount signal that described signal processing module gathers described capture card carries out signal to be processed.

Described human-computer interface module realizes the dynamic demonstration of band saw machine sawing load characteristic.

The utility model has the advantages that:

1, simple with existing band sawing machine mechanism assembling, less on the actual production impact;

2, detection system fast response time, information storage is large, and degree of accuracy is higher.

3, the device hardware configuration is simple, analyzes the main software that leans on of identification and realizes, is convenient to upgrading and safeguards.

Description of drawings

Fig. 1 is band saw vibrating signal acquisition hardware scheme of installation.

Fig. 2 is band saw vibrating signal acquisition processing module schematic diagram.

Fig. 3 is sawing load characteristic on-line intelligence decision-making work schematic diagram.

Fig. 4 is rough set inference machine fundamental diagram.

Embodiment

Below in conjunction with accompanying drawing, the utility model is further described.

As shown in Figure 1, the current vortex sensor module comprises quadruplet current vortex sensor 1 and with the support 5 of base 4.The probe of described current vortex sensor 1 is fixedly mounted on respectively on quadruplet support 5, and described base 4 is fixed on band saw machine guide piece 3.During detection, regulate the stretching, extension attitude of support 5, make the probe vertical of described current vortex sensor 1 be right against the saw band part of band saw for metal 2, and the detection faces of popping one's head in is positioned at same level.When band saw was worked, bands for band can produce the horizontal dither offset based on the equilibrium position, and the size of its off-set value is converted to the current signal variable quantity via current vortex sensor 1, provided system further analyzing and processing.

As shown in Figure 2, the signal acquisition module main circuit will comprise the analog input module, A/D modular converter, high-speed counter module and fifo module.After current vortex sensor 1 detected the bands for band dither offset, output simulation (electric current) signal 1-4 was to the analog input port of change-over panel module, and concrete connected mode is the mode changeover signal of single-ended connection.

By external cable, the simulating signal of inputting the change-over panel module is directly transferred to capture card, carry out the high-speed a/d conversion of simulating signal.Before the conversion beginning, capture card also will carry out passage scanner uni gain calculation process, so that Optimized Simulated signal conversion efficiency and precision.Simultaneously, capture card also provides programmable timer sum counter, is used to the A/D conversion that trigger pulse is provided.The timer/counter chip is 82C54, contains 3 16 10MHz clocks.A counter is wherein arranged as event counter, be used for the event of input channel is counted.Two other counter stage is linked togather, as pulsed 32 bit timing devices.

Capture card is used for the AD conversion with sampling FIFO (first-in first-out) impact damper of 1K.Described FIFO core buffer can be stored the 1KA/D sampled value, after starting the interrupt request of impact damper, can realize continuous high speed data-switching and higher operating system warning function.

, transfer in PC and wait for based on digital signal filter, sampling, the digital signal processing of the mathematical algorithms such as Fourier transform, correlation analysis by pci interface through the data after the preliminary conversion of capture card and computing.Through the characteristic signal after digital processing repeatedly, after the theoretical model analysis of expert system, show band saw sawing load characteristic and load variations by man-machine interface (HMI) in based on fault diagnostics, and the intelligent decision evaluation that comprehensively draws the sawing operating mode.

As shown in Figure 3, the specific works principle of digital signal processing, computing and analysis is that when band saw work moved, described current vortex sensor 1 detected band saw dither offset amount, output analog signals value ai (t).Described signal value ai (t) carries out the AD conversion via described signal acquisition module, and wherein said signal acquisition module is furnished with automatic channel/gain scan circuit and filter circuit of pressure-stabilizing, can carry out preposition pre-service to described signal value ai (t).

After described signal acquisition module AD conversion, output digit signals value x (t) is to signal processing module.Described signal processing module for the ease of analytical calculation, intercepts time-limited one section with the time series of signal after the conversion sampling and calculates, and remainder is considered as zero and will not analyzes.Namely adopt window function w (t) to go to take advantage of sampled signal (time series), (t) ﹒ w (t), its frequency spectrum function are [X (f) * W (f)] to x.

Adopt fast fourier transform algorithm (FFT), (t) ﹒ w (t) is transformed into the discrete frequency sequence, Output rusults X (f) with discrete time series x _p=[X (f) * W (f)] ﹒ D (f).Thus, can utilize computing machine effectively to process time-limited discrete-time series and time-limited discrete frequency sequence.

Described current vortex sensor 1 has gathered four signal value ai (t), and in order to study the relation between each signal value, further band saw flutter eigenwert is extracted in the application relativity analysis.Namely use autocorrelation function difference periodic function, decay broadband random noise, and can determine the frequency of periodic factors, the fixed frequency that records thus the band saw same point reach working conditions change and the corresponding relation that occurs in time.Use cross correlation function, can utilize with frequently relevant, different incoherent characteristics frequently record the situation of change of fixed frequency under time and operating mode impact between the band saw difference.

Vibrating signal after treatment can extract eigenwert, utilizes the expert system based on rough set (RSDA), and the sawing operating mode is carried out the on-line intelligence decision-making.In described expert system, operation flutter curve family and the relevant frequency spectrum analytical information of band saw import experts database as expertise, and described eigenwert is temporary in database as the input message of system, through the compare of analysis of diagnostic model, the classification that asks a question.At this moment, the Question Classification that system proposes is more numerous and diverse, has some just to be present in theoretical case.Therefore, based on real system, need through rough set (RSDA), Question Classification to be carried out yojan.

As shown in Figure 4, described rough set (RSDA) is correlativity and dependent a kind of notation method between a kind of analysis data, utilize RSDA from extracting data rule, searching determinant attribute and property value, predict and decision-making, fully from data-driven, so system has the function of self study, self diagnosis due to the generation of rule.

Described expert system is through diagnosis and decision-making, and finally by man-machine interface, i.e. man-machine interface (HMI) output band saw sawing operating mode intelligent decision is estimated.

Claims (1)

1. sawing Weight detector based on the band saw for metal buffet characteristic, it is characterized in that: this device is comprised of current vortex sensor module, signal acquisition module, signal processing module, human-computer interface module; Wherein the current vortex sensor module comprises the support of quadruplet current vortex sensor and quadruplet band base;

Described current vortex sensor module, its quadruplet current vortex sensor is divided equally on the support that is fixed in quadruplet band base, the band saw dither offset amount that when being respectively used to measure band saw work, workpiece both sides sawing produces;

Described support with base is fixed on the guide piece of band saw machine, and adjustable support makes the probe of quadruplet current vortex sensor all in same level and perpendicular to band saw for metal saw band part;

The band saw dither offset amount that when described current vortex sensor is used for measuring band saw work, workpiece both sides sawing produces;

Described signal acquisition module adopts change-over panel and capture card, the current vortex sensor signal output part is connected with the analog input Wiring port of change-over panel, described change-over panel is connected by cable with described capture card, and described capture card is connected with PC PCI slot;

The band saw dither offset amount signal that described signal processing module gathers described capture card carries out signal to be processed;

Described human-computer interface module realizes the dynamic demonstration of band saw machine sawing load characteristic.

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