CN204159809U - A kind of on-line monitoring system be shaped for steel ball cold heading - Google Patents
A kind of on-line monitoring system be shaped for steel ball cold heading Download PDFInfo
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- CN204159809U CN204159809U CN201420580494.0U CN201420580494U CN204159809U CN 204159809 U CN204159809 U CN 204159809U CN 201420580494 U CN201420580494 U CN 201420580494U CN 204159809 U CN204159809 U CN 204159809U
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Abstract
The utility model discloses a kind of on-line monitoring system be shaped for steel ball cold heading, comprise dynamic and static mould displacement signal acquisition device, displacement signal acquisition device is connected with single-chip computer control system, single-chip computer control system is connected with man-machine interface, described dynamic and static mould displacement signal acquisition device gathers the change in displacement between dynamic model, quiet mould, and change in displacement is converted into voltage change; Voltage signal is transferred to single-chip computer control system, and single-chip computer control system shows after processing voltage signal in man-machine interface.In the utility model, adopt micro-displacement sensor to monitor the relation of dynamic model displacement x t change in time, gather the Changing Pattern of material section forming quality in forming process, in actual production process, when die wear, material section are elongated, the link such as to shorten occurs abnormal, displacement signal change will reflect on envelope curve.
Description
Technical field
The utility model relates to a kind of on-line monitoring system be shaped for steel ball cold heading.
Background technology
Steel ball, as the vital part in mechanized equipment field, is mainly used in bearing, valve, lead screw transmission, polishing etc., is machinery, automobile industry and military project, the requisite part of aerospace industry.The basic machining process of current domestic steel ball is: raw material → cold-heading → photosphere → heat treatment → hard grind → early grind → lappingout → superfinishing grinds → optical appearance → cleaning rust-proof → product inspection → packaging.Cold-heading base can ensure good Product Precision and mechanical performance, and thus middle-size and small-size steel ball base generally adopts cold-heading processing technology.Cold-heading is as the first operation of steel ball processing, and its defect that becomes second nature has diffusivity, heredity, disguise, often comes out in subsequent handling, is main hidden danger of quality and substandard products source.Endless belt defect (without endless belt or endless belt excessive) be the prevailing quality defect that steel ball is embarked on journey in process.
Current domestic steel ball cold heading equipment only performs mechanical reciprocating motion, lacks process and detects; Traditional employing dedicated test utensil carries out the method for manual detection, and detection efficiency is low, and measurer is easy to wear, in production process, problem can not by Timeliness coverage and correction, cause blank quality poor stability, often mix bad product in qualified steel ball blanks, have a strong impact on product qualified rate.
It is the automatic detection device disclosing a kind of steel ball high-speed cold heading machine in [201310519608.0] at number of patent application, , comprise the PLC be fixed in cold headers frame, cold headers panel 1, module 2, fixing formwork 3, fixing ball mould 4, movable formwork 5 and movable balls mould 6, described module 2 is fixedly connected with cold headers panel 1, fixing formwork 3 is fixedly mounted in module 2 by backing plate 9, fixing ball mould 4 is arranged in fixing formwork 3, movable balls mould 6 is arranged in movable formwork 5, movable formwork 5 is connected with the high-speed electric expreess locomotive of cold headers by eccentric wheel, this automatic detection device also comprises pressure sensor 7, the panel 1 of cold headers is provided with hole 8, and load pressure sensor 7 in hole 8, pressure sensor 7 is connected with PLC on cold headers by wire,
The automatic detection device of existing patent, pressure sensor needs to be arranged in the hole on cold headers panel, installs inconvenient, and carry out scrap build trouble on the basis of existing cold headers, need again to punch sensor installation; Adopt PLC to control, cost is higher.And the value only by obtaining surge is come to judge that method that whether ball is qualified is comprehensive according to pressure limit, should according to pressure in cold-heading process--time signal sets up envelope curve judgement.
Utility model content
In order to solve the deficiency that prior art exists, the utility model discloses a kind of on-line monitoring system be shaped for steel ball cold heading, by to dynamic model in cold-heading process, quiet mould displacement signal carries out Real-Time Monitoring and record, and automatically set up production monitoring standard by self-learning algorithm, On-line testing monitoring also analytic signal feature, Real-Time Monitoring cold heading sphere blank time-displacement curve in process, by the matching degree of correlation analysis algorithm analysis and production monitoring standard, make there is problem in production process by Timeliness coverage, there is quality tracing and optimization, the function such as abnormal alarm and equipment protection.
For achieving the above object, concrete scheme of the present utility model is as follows:
A kind of on-line monitoring system be shaped for steel ball cold heading, comprise dynamic and static mould displacement signal acquisition device, displacement signal acquisition device is connected with single-chip computer control system, single-chip computer control system is connected with man-machine interface, described dynamic and static mould displacement signal acquisition device gathers the change in displacement between dynamic model, quiet mould, and change in displacement is converted into voltage change; Described voltage signal is transferred to single-chip computer control system, and described single-chip computer control system shows after processing voltage signal in man-machine interface.
Described dynamic and static mould displacement signal acquisition device comprises micrometric displacement current vortex sensor, be arranged on cold headers fixes the fixed support on formwork and to be arranged on movable formwork and for the fixing sensor block of sensor sensing; Described micrometric displacement current vortex sensor is arranged on fixed support.
Described single-chip computer control system mainly comprises singlechip chip, A/D modular converter, warning device.A/D modular converter is all connected with singlechip chip with warning device;
Described warning device mainly comprises relay and red alarm lamp, and relay controls the break-make of alarm lamp circuit;
Described man-machine interface is touch screen human-computer interface, is connected with the serial communication of singlechip chip by Serial Port Line;
Described micrometric displacement current vortex sensor, single-chip computer control system, man-machine interface are all powered by Systematical control power circuit;
Described Systematical control power circuit comprises rotary switch, power supply indicator and technical grade AC-DC Switching Power Supply, and 220V alternating current is converted to 24V and 5V direct current and exports by AC-DC Switching Power Supply.
Micrometric displacement current vortex sensor is by the principle of eddy current effect, and the relative position of Measurement accuracy measured body (must be metallic conductor) and probe end face, and change in displacement is converted into voltage change.Micrometric displacement current vortex sensor and sensor block are arranged on quiet mould and dynamic model side respectively, and in production process, the distance change transitions of cold-heading carcass is voltage change signal.
Dynamic and static mould displacement signal acquisition device be used in cold-heading process between dynamic model, quiet mould the signal of change in displacement gather;
Man-machine interface is for showing running parameter and the cold headers duty of displacement signal in cold-heading process;
Single-chip computer control system is delivered to man-machine interface after being used for the displacement signal process collected by displacement transducer and is shown in real time, by self-learning algorithm, the displacement signal in one section of steady production process is recorded, and automatically set up envelope curve as production monitoring standard, Real-Time Monitoring cold heading sphere blank time-displacement curve in process, by the matching degree of correlation analysis algorithm analysis and production monitoring standard, produce alarm signal when actual production process test signal exceeds envelope curve or automatically close plant equipment power supply;
The method for supervising of described on-line monitoring system is as follows:
First be that learning training process is carried out to monitoring system, set up working template by learning training, mainly comprise 3 steps:
Step 1: under the monitoring of operating personnel, and judge that whether the quality that steel ball is shaped is qualified by operating personnel, only record the time m-displacement signal of qualified steel ball blanks;
Step 2: discrete sampling is carried out to qualified steel ball blanks, specific as follows:
To n cold-heading steel ball qualifying signal sampling; Each signal through A/D conversion after, the discrete array [x being a length and being fixed as j
ij] (i=1,2 ... n), (j=1,2 ... N); Be discrete point by each load signal by continuous analog quantitative change like this, for medium filtering provides numerical value to originate.Be discrete point by each load signal by continuous analog quantitative change like this, for medium filtering provides numerical value to originate.
Step 3: circle median filter:
Carry out ascending order arrangement to each corresponding points in n group data, x (x > 3) the individual data in the middle of selecting are preserved; If there is new data, then carry out the sampling of n-x group waveform, composition n group data, ascending order arranges; But which is recorded is the legacy data remained in the past, and which is new data; According to the various different arrangements possibility of new legacy data, obtain the waveform signal that x group is new, so circulate.If do not have new Waveform Input, from the remaining x of an each some data, the data in the middle of selecting are preserved, and obtain reference waveform signal, automatically set up envelope curve as production monitoring standard, be kept in SCM system;
N above, x all represents natural number.
After monitoring system has carried out learning training, enter the normal production work stage, entered into step 4.Under nominal situation, each cold-heading process time m-displacement signal curve characteristic index substantially identical with template, once there is shaping fault, signal curve will produce corresponding ANOMALOUS VARIATIONS.
Step 4: when the production phase is detected, dynamic and static mould displacement signal is gathered at any time by micrometric displacement current vortex sensor, adopt correlation analysis algorithm that the production monitoring standard in gathered signal and step 3 is carried out matching operation, produce alarm signal when actual production process test signal exceeds envelope curve or automatically close plant equipment power supply, when not exceeding envelope curve, equipment normally runs.
The beneficial effects of the utility model:
In the utility model, adopt micro-displacement sensor to monitor the relation of dynamic model displacement x t change in time, gather the Changing Pattern of material section forming quality in forming process, adopt self-learning algorithm automatically to set up envelope curve as production monitoring standard, the width of optimum envelope curve can be calculated by automatic analysis according to the every bit on displacement curve.In actual production process, when die wear, material section are elongated, the link such as to shorten occurs abnormal, displacement signal change will reflect on envelope curve;
The utility model is increased in line monitoring system on the basis of traditional cold-heading process, production efficiency is improved greatly, problem in Timeliness coverage cold-heading process, in the labor-saving uniformity that improve product quality simultaneously, achieves the on-line monitoring be shaped for cold-heading process ball base.
Accompanying drawing explanation
Fig. 1 steel ball cold heading mechanism schematic diagram;
Fig. 2 (a)-(b) automatic learning envelope curve schematic diagram;
Fig. 3 standard signal learning algorithm flow chart;
Fig. 4 sensor installation diagram;
Fig. 5 single-chip computer control system figure;
Fig. 6 systematic functional structrue figure;
In figure: 1. eccentric wheel 2. connecting rod 3. slide block 4. adjustment block 5. dynamic model 6. cover half.
Detailed description of the invention
Below in conjunction with accompanying drawing, the utility model is described in detail:
Be the structural principle sketch of cold-heading campaign as shown in Figure 1, figure comprises eccentric wheel 1, connecting rod 2, slide block 3, adjustment block 4 dynamic model 5, cover half 6.Ball cold header cold-heading process can be reduced to slider-crank mechanism and drive dynamic model motion, thus makes bar crimp between dynamic and static mould, final cold-heading balling-up.Wherein adjustment block can adjust up and down, for regulating the range of dynamic model (namely adjusting the final position of dynamic model), thus the endless belt size of adjustment steel ball blanks.
Set up coordinate system in the drawings, calculate the relational expression of displacement x about angle θ of slide block.Because slide block and eccentric deflection center are coaxial, therefore in △ OAB, the abscissa of OB, namely dynamic model displacement movement equation is:
Due to θ=ω t, substitute into above formula, dynamic model displacement be converted into displacement movement function in time with the characteristics of motion of angle:
When cold headers are unloaded, dynamic model displacement x with the movement function of angle θ, time t as shown in two formula above.When in actual cold upsetting production process, have ess-strain produce from material section to the process of cold-heading balling-up base, material section can produce reaction force to dynamic model in the process of cold-heading, and reaction force can make crank, connecting rod produce elastic deformation.Therefore, in the process of punching press cold-heading, dynamic model displacement x will be no longer above described in formula with the movement function relation of angle θ, time t, and certain change can occur.
Based on above-mentioned principle, the utility model discloses the on-line monitoring system be shaped for steel ball cold heading, comprise dynamic and static mould displacement signal acquisition device, displacement signal acquisition device is connected with single-chip computer control system, and single-chip computer control system is connected with man-machine interface;
The displacement signal acquisition device fixed support of installing micrometric displacement current vortex sensor and sensor block that displacement transducer is responded to as shown in Figure 4, displacement transducer is fixed in the hole of support, by two screwed hole screw fastenings on top, four screws of support both sides are fixed on fixing formwork side.Sensor has that functional reliability is good, measurement category is wide, highly sensitive, resolution ratio is high, fast response time, interference resistance by force, not by advantages such as medium influence such as greasy dirts.The displacement signal collected is converted into voltage signal and sends into single-chip microcomputer;
Single-chip computer control system comprises singlechip chip as shown in Figure 5, A/D modular converter, warning device.A/D modular converter is all connected with singlechip chip with alarm output device, and man-machine interface is communicated by UART0 with single-chip microcomputer;
Being illustrated in figure 6 the design drawing of system man-machine interface, mainly containing four interfaces composition, is 1. starting-up interface, 2. homepage interface, 3. mode of learning interface, 4. optimum configurations interface respectively.
In use, open the rotary switch in system power supply circuit, power supply indicator is bright, first shows starting-up interface after man-machine interface powers on, and clicks in starting-up interface and enters into homepage interface after " entering "; Order volume, actual performance, order surplus, information such as residue process time, processing speed etc. can be shown in real time on the left of homepage interface, right side comprises the options such as mode of learning, production model, optimum configurations, help, mid portion is displacement information viewing area, as long as shown in real time with the form of block diagram by the displacement collected; After click " mode of learning " enters into mode of learning, display mode of learning interface, mode of learning is started after " startup " is clicked at mode of learning interface, interface display is learning and recording learning result, within 1-2 minute, click " stopping " button later, now then display learning outcome is preserved by drawing frame, sets up production monitoring standard; Under production model, drawing frame shows displacement information change that sensor collects in real time and compares with the production monitoring standard set up, when larger with monitoring standard difference in a period of time, and warning device work, remind workman to shut down, continue after regulating cold headers to produce; The parameter of Drawing zone X-axis with Y-axis can be set at optimum configurations interface.
Be illustrated in figure 6 main function of system:
(1) quality analysis: on-line analysis displacement signal, sets up production monitoring standard, differentiates forming defects;
(2) data store and read: utilize the inner FLASH of human machine interface screen, by process data, production leadtime information etc. is stored into system;
(3) display module: realize visualized operation, interactive setting.Realize the real-time display of significant data, comprising: the block diagram, operation setting menu etc. of performance graph, impact energy;
(4) time tag: machining information is corresponding with process time, realizes product and adds up in shifts and inquire about with historical record;
(5) setting parameter: man-machine interactive arranges important parameter, as internal gain, displacement signal sample rate etc.;
(6) important parameter power-failure memory: preserve the parameter set, start is read automatically, and the monitoring device of non-first use exempts to arrange.
In the utility model, adopt micro-displacement sensor to monitor the relation of dynamic model displacement x t change in time, gather the Changing Pattern of material section forming quality in forming process, adopt self-learning algorithm automatically to set up envelope curve as production monitoring standard, the width of optimum envelope curve can be calculated by automatic analysis according to the every bit on displacement curve.In actual production process, when die wear, material section are elongated, the link such as to shorten occurs abnormal, displacement signal change will reflect, if Fig. 2 is automatic learning envelope curve schematic diagram on envelope curve;
When the on-line monitoring system that steel ball cold heading is shaped runs learning algorithm, under the monitoring of operating personnel, judge that whether the quality that steel ball is shaped is qualified by operating personnel, only record the displacement signal of qualified steel ball blanks.List standard signal learning algorithm flow process as shown in Figure 3, obtain discretization load signal data point by data acquisition, the study of whole waveform is modified to the study to point.Mainly contain sample variance and circle median filter two step.
(1) sample variance: carry out n cold-heading steel ball qualifying signal sampling; Each signal through A/D conversion after, the discrete array [x being a length and being fixed as N
iN] (i=1,2 ... n).Be discrete point by each load signal by continuous analog quantitative change like this, for medium filtering provides numerical value to originate.
(2) circle median filter: carry out ascending order arrangement to each corresponding points in n group data, 3 data in the middle of selecting are preserved.If there is new data, then carry out the sampling of n-3 group waveform, composition n group data, ascending order arranges; But which is recorded is the legacy data remained in the past, and which is new data.Because legacy data is through screening, the information content comprised is larger than new data, and its priority is high, according to the various different arrangement of new legacy data may, obtain 3 groups of new waveform signals, so circulate.If do not have new Waveform Input, from remaining 3 data of each point, the data in the middle of selecting are preserved, and obtain reference waveform signal.
Claims (7)
1. the on-line monitoring system be shaped for steel ball cold heading, it is characterized in that: comprise dynamic and static mould displacement signal acquisition device, displacement signal acquisition device is connected with single-chip computer control system, single-chip computer control system is connected with man-machine interface, described dynamic and static mould displacement signal acquisition device gathers the change in displacement between dynamic model, quiet mould, and change in displacement is converted into voltage change; Described voltage signal is transferred to single-chip computer control system, and described single-chip computer control system shows after processing voltage signal in man-machine interface.
2. as claimed in claim 1 for the on-line monitoring system that steel ball cold heading is shaped, it is characterized in that: described dynamic and static mould displacement signal acquisition device comprises micrometric displacement current vortex sensor, be arranged on cold headers fixes the fixed support on formwork and to be arranged on movable formwork and for the fixing sensor block of sensor sensing; Described micrometric displacement current vortex sensor is arranged on fixed support.
3., as claimed in claim 1 for the on-line monitoring system that steel ball cold heading is shaped, it is characterized in that: described single-chip computer control system comprises singlechip chip, A/D modular converter, warning device; A/D modular converter is all connected with singlechip chip with warning device.
4., as claimed in claim 3 for the on-line monitoring system that steel ball cold heading is shaped, it is characterized in that: described warning device mainly comprises relay and red alarm lamp, and relay controls the break-make of alarm lamp circuit.
5., as claimed in claim 1 for the on-line monitoring system that steel ball cold heading is shaped, it is characterized in that: described man-machine interface is touch screen human-computer interface, is connected with the serial communication of singlechip chip by Serial Port Line.
6., as claimed in claim 2 for the on-line monitoring system that steel ball cold heading is shaped, it is characterized in that: described micrometric displacement current vortex sensor, single-chip computer control system, man-machine interface are all powered by Systematical control power circuit.
7. as claimed in claim 6 for the on-line monitoring system of steel ball cold heading shaping, it is characterized in that: described Systematical control power circuit comprises rotary switch, power supply indicator and technical grade AC-DC Switching Power Supply, 220V alternating current is converted to 24V and 5V direct current and exports by AC-DC Switching Power Supply.
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| CN201420580494.0U CN204159809U (en) | 2014-10-09 | 2014-10-09 | A kind of on-line monitoring system be shaped for steel ball cold heading |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104308060A (en) * | 2014-10-09 | 2015-01-28 | 济南大学 | Online monitoring system for steel ball cold heading forming and monitoring method |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104308060A (en) * | 2014-10-09 | 2015-01-28 | 济南大学 | Online monitoring system for steel ball cold heading forming and monitoring method |
| CN104308060B (en) * | 2014-10-09 | 2016-03-02 | 济南大学 | A kind of method for supervising of the on-line monitoring system for steel ball cold heading shaping |
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| CF01 | Termination of patent right due to non-payment of annual fee |
Granted publication date: 20150218 Termination date: 20171009 |
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| CF01 | Termination of patent right due to non-payment of annual fee |