CN210678020U - Online and in-place detection system for cutter damage in clean cutting environment - Google Patents
Online and in-place detection system for cutter damage in clean cutting environment Download PDFInfo
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- CN210678020U CN210678020U CN201921149988.2U CN201921149988U CN210678020U CN 210678020 U CN210678020 U CN 210678020U CN 201921149988 U CN201921149988 U CN 201921149988U CN 210678020 U CN210678020 U CN 210678020U
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Abstract
The utility model discloses an online and on-site detection system for cutter damage in a clean cutting environment, which comprises an online prejudgment and identification system, an on-site detection system, a cleaning system for cleaning cutters and a computer; the online prejudging and identifying system is used for measuring the vibration quantity of the cutting position, the change value of the voltage and the current of the spindle, the change value of the cutting force and the acoustic signal in real time; the in-place detection system is used for acquiring a side edge image and a bottom edge image of the cutter in place; and the data acquisition card and the image acquisition card respectively transmit the signals detected by the sensors and the images acquired by the vision system to the computer. The utility model discloses the accurate detection of cutter wearing and tearing can be present.
Description
Technical Field
The utility model belongs to a cutter detects technical field, especially a cutter damage is online and detecting system on throne under clean cutting environment.
Background
In the automatic machining process, monitoring the wear state of the cutter is one of important means for reducing the manufacturing cost, reducing the manufacturing environment hazard and ensuring the normal and efficient operation of a production and manufacturing system and the product quality. The cutter abrasion has obvious influence on the processing precision, the processing quality and the processing efficiency of products, if the cutter abrasion is not found in time, parts can be scrapped, a machine tool is stopped, the machine tool is damaged, even a workpiece is broken to hurt people, and the processing benefit and the economic benefit are directly influenced. Industrial statistics show that tool wear is the primary factor causing machine tool failure, and the resulting downtime accounts for 1/5-1/3 of the total downtime of the numerical control machine tool. Therefore, the tool wear state monitoring is carried out in the batch processing process of the numerical control processing system, and the problem to be solved is compelled to be solved under the background of intelligent manufacturing.
Chinese patent publication No. CN102564314A discloses an orthogonal vision detection system for detecting the wear state of an end mill, which requires the shutdown to disassemble a cutter for detection in a laboratory, occupies production time, is not beneficial to the improvement of production benefit and economic benefit of a flexible manufacturing system, and cannot detect the state change process of grinding/damage of the cutter in the machining process; chinese patent publication No. CN106840028A discloses an in-situ measurement method and device for tool wear, wherein a vision detection system is mounted on the side of a tool of a machine tool for detection, the vision detection system is fixed, so that image acquisition for the tool at multiple angles cannot be realized, the detection of the tool wear area is incomplete, the automatic cleaning of the cutting detection environment is not considered, and a vision system protection device and a tool cleaning device are lacked; chinese patent publication No. CN107553219A discloses a tool wear monitoring method based on multiple sensor composite signals, which has many interference factors affecting the detection result due to complex and various cutting conditions, and is prone to cause tool wear/damage misjudgment due to other fault factors, resulting in tool waste. In summary, the existing detection methods all have certain defects, a set of cutter abrasion detection system with high automation degree and high efficiency and precision is lacked, and the improvement of the production benefit and the economic benefit of the flexible manufacturing system is seriously hindered.
SUMMERY OF THE UTILITY MODEL
An object of the utility model is to provide a cutter damage is online and detecting system on throne under clean cutting environment to realize the accurate detection of cutter wearing and tearing.
Realize the utility model discloses the technical solution of purpose does:
a cutter damage on-line and on-line detection system in a clean cutting environment comprises an on-line prejudging and identifying system, an on-line detection system, a data acquisition card, an image acquisition card, a cleaning system for cleaning a cutter and a computer;
the online prejudging and identifying system comprises a vibration sensor, a voltage sensor, a force sensor, a current sensor and an acoustic emission sensor; the vibration sensor is used for measuring the vibration quantity of a cutting position in the machining process of the machine tool in real time; the voltage sensor and the current sensor are respectively used for measuring the change values of the main shaft voltage and the current in the machining process of the machine tool in real time; the force sensor is used for measuring the change value of the cutting force in the machining process of the machine tool in real time; the acoustic emission sensor is used for measuring an acoustic signal of the cutter during cutting in real time;
the in-place detection system comprises a robot and a vision system; the robot is arranged on one side near the cutting position of the machine tool machining center; the robot drives the vision system to collect side blade images and bottom blade images of the cutter in place; and the data acquisition card and the image acquisition card respectively transmit the signals detected by the sensors and the images acquired by the vision system to the computer.
Compared with the prior art, the utility model, it is showing the advantage and is:
(1) the utility model discloses a tool that synthesizes on line and on the throne grinds/damage detection method, has realized the dual promotion of tool damage detection efficiency and reliability: the online prejudging and identifying system carries out preliminary prejudging on the grinding/damage of the cutter, and after the grinding/damage of the cutter is preliminarily judged, the on-site detection system acquires a cutter image to carry out precision detection on the grinding/damage of the cutter, and finally judges the grinding/damage degree of the cutter, the grinding/damage type of the cutter and whether the cutter needs to be replaced or not, so that the error rate of the grinding/damage detection of the cutter is reduced; the online real-time prejudgment process enables the in-place precision detection to be carried out without collecting cutter images at frequent intervals, and image collection is carried out only after the cutter is prejudged to be worn/damaged, so that the data collection amount of the in-place precision detection is reduced, the shutdown times are reduced, the fault-free running time of machine tool equipment is effectively prolonged, and the production benefit and the economic benefit of the flexible manufacturing system are greatly improved.
(2) The utility model discloses a software robot drive camera system of shooing carries out image acquisition, and flexibility is better, and adaptation lathe machining center inner space that can be better is narrow and small, the many characteristics of obstacle, and degree of automation is higher, has realized the intelligent detection that the cutter ground/was damaged.
(3) The utility model can effectively prevent the cutting tool from being stained with the cutting scraps during the detection by arranging the starting and cleaning high-pressure spray gun, the lens wiper and the electric window, and simultaneously keep the lens clean and prevent the cutting scraps from scratching the lens and cutting fluid, water vapor and the like from being adhered to the lens in the processing process, thereby providing a clean cutting detection environment for the tool grinding/damage detection; the detection precision is improved.
Drawings
Fig. 1 is a schematic general structure diagram of a detection system.
Fig. 2 is a schematic view of a vision system.
Fig. 3 is a schematic diagram of a cleaning system.
Fig. 4 is a schematic structural diagram of the lens wiper.
FIG. 5 is a schematic diagram of an industrial camera capturing an image of a side edge of a tool.
FIG. 6 is a schematic view of an industrial camera capturing an image of the bottom edge of a tool.
Fig. 7 is a schematic view of the system work flow of the present invention.
Detailed Description
The present invention will be further described with reference to the accompanying drawings and specific embodiments.
With reference to fig. 1-6, the system for detecting tool damage in a clean cutting environment comprises an online pre-judging and identifying system, an on-line detecting system, a data acquisition card 15, an image acquisition card 13, a cleaning system, and a computer 14;
the online prejudging and identifying system comprises a vibration sensor 1, a voltage sensor 2, a force sensor 3, a current sensor 4 and an acoustic emission sensor 5; the vibration sensor 1 is arranged near the cutting position or at the tool shank of the machine tool machining center 6 and used for measuring the vibration quantity near the cutting position in the machining process of the machine tool in real time; the voltage sensor 2 and the current sensor 4 are arranged at a control cabinet of a machine tool machining center 6 and are used for measuring the change values of the main shaft voltage and the current in the machining process of the machine tool in real time; the force sensor 3 is arranged at a workbench of a machine tool machining center 6 or a machine tool spindle clamping tool 16 and is used for measuring a change value of cutting force in the machine tool machining process in real time; the acoustic emission sensor 5 is fixed near the cutting position of the machine tool machining center 6 through a magnetic base and is used for measuring an acoustic signal of the cutter 16 during cutting in real time;
the data acquisition card 15 transmits signals detected by each sensor to the computer 14; the in-place detection system comprises a robot 78 and a vision system; the robot 78 is disposed on one side near the cutting position of the machining center 6; the vision system is arranged at the tail end of the robot 78, and the robot 78 drives the vision system to collect the side edge image and the bottom edge image of the cutter 16 in place;
the cleaning system is used for cleaning the cutter 16, and the accuracy of the image acquired by the vision system is ensured;
the computer 14 is used for extracting time domain features and frequency domain features of vibration, current, voltage, cutting force and acoustic emission signals collected by each sensor and fusing data; the extracted data features are taken as a vertical axis, time is taken as a horizontal axis to generate a change curve, if the curve exceeds a set threshold value in the machining process, an early warning is sent out, and the machine tool is stopped; processing the image of the cutter 16 acquired by the vision system, calculating the damage degree of the cutter, judging whether the cutter needs to be replaced or not, and displaying the cutter on a display screen; when the computer 14 judges that the data acquired by the online prejudging and identifying system is abnormal, the machine tool stops, the cleaning system starts to clean the cutter 16, the cutter 16 rotates, and the vision system starts to acquire a side edge image and a bottom edge image of the cutter 16; the type and degree of damage to the tool 16 are further determined. The computer 14 is also used for controlling the operation of the machine tool machining center 6 and the robot 78, and controlling the frequency of one circle of rotation of the cutter so as to ensure that the side edge image of the cutter 16 is completely shot;
further, the vision system 7 includes a connector 75, a camera mount 74, an industrial camera 70, a lens 71, a ring light source 72; the camera mount 74 is fixed to the end of the robot 78 by a connector 75; the industrial camera 70 is fixed on a camera mount 74; the lens 71 is connected with the industrial camera 70, and the annular light source 72 is arranged at the front end of the lens 71; the robot 78 drives the industrial camera 70 to capture an image of the tool 16 in place.
Further, the robot 78 adopts the existing purchased soft robot, has good flexibility, and can better adapt to the characteristics of narrow space and more obstacles in a machine tool machining center.
Further, when the side edge image of the cutter 16 is collected, the cutter needs to rotate for a circle for n times, and the angle of 2 pi/n is rotated every time, wherein n is greater than 2, so that the side edge image of the cutter 16 is completely shot;
further, the cleaning system comprises an electric window 9, a pneumatic cleaning high-pressure spray gun 11, an air compressor 10, a rubber hose 12 with a nozzle, and a lens protection cover 73; the electric window 9 is arranged near the cutting position of the machine tool machining center 6, is arranged between the vision system and the prop 16, and is automatically opened/closed for the robot 78 when the precision detection of the grinding/damage of the cutter is carried out, so that the vision system 7 can be isolated from the machining environment, chips generated during machining are prevented from scratching the lens 71, cutting fluid wets the lens 71, and water vapor is prevented from being attached to the lens 71. When image acquisition is carried out, the electric window 9 is opened, the robot 78 extends into the machine tool machining center 6 to drive the industrial camera 70 to finish image acquisition of the side edge and the bottom edge of the cutter 16, after the image acquisition is finished, the robot 78 drives the industrial camera 70 to return to the original position, and the electric window 9 is closed; the pneumatic cleaning high-pressure spray gun 11 is connected to an air compressor 10, the rubber hose 12 is connected to a spray gun port, one end of a nozzle of the rubber hose 12 is fixed at the tail end of a robot 78 execution through a fixing frame 77, and before image acquisition is carried out on the cutter 16, the rubber hose 12 follows the robot 78 to achieve the purpose of cleaning the cutter 16; the lens protection cover 73 is mounted at the front end of the annular light source 72 and is used for protecting the lens 71 and the annular light source 72 and preventing dirt such as dust, cutting scraps and cutting fluid from being contaminated.
Further, the cleaning system also comprises a lens wiper 8, the lens wiper 8 is fixed near the robot 78, and the electric window 9 isolates the lens wiper from the processing environment; the lens wiper 8 comprises a lens wiping cotton 81 and a bracket 82, wherein the lens wiping cotton 81 is fixed at the upper end of the bracket 82; when the lens 71 and the annular light source 72 are stained with dust or dirt, the robot 78 drives the camera lens 71 to wipe back and forth on the wiping cotton 81;
the utility model discloses a detecting system's working process does:
the multi-sensor cooperation online real-time tool grinding/damage pre-judgment method comprises the following steps:
collecting data: running the machine tool to carry out actual processing, and acquiring vibration, current, voltage, cutting force and acoustic emission signals of the machine tool in real time by using a vibration sensor, a current sensor, a voltage sensor, a cutting force sensor and an acoustic emission sensor;
feature extraction and fusion: extracting time domain characteristics and frequency domain characteristics which can objectively reflect the grinding/damage state of the cutter according to the collected vibration, current, voltage, cutting force and acoustic emission signals in the formulas (1) to (8):
time domain characteristics:
xMax＝max(|xi|) (3)
frequency domain characteristics:
xirepresents a monitoring signal collected by the ith sensor in a certain time period in the cutting process, wherein i is 1,2,3, …, N; n is the number of sensors; mu is the mean value of the monitoring signals collected in a certain time period in the cutting process, is the static part of the monitoring signals and reflects the variation trend of the monitoring signals; x is the number ofRMSThe root mean square of the monitoring signals collected in a certain time period in the cutting process represents the average energy of the monitoring signals in a given certain time period, and reflects the intensity of the monitoring signals; x is the number ofMaxThe maximum instantaneous amplitude of the monitoring signal is represented as the sum of the maximum values of the monitoring signals collected in a certain time period in the cutting process; x is the number ofStdThe dynamic part of the monitoring signal is the standard deviation of the monitoring signal acquired in a certain time period in the cutting process, and reflects the fluctuation degree of the monitoring signal near the mean value; x is the number ofSkeReflecting the asymmetry degree of the monitoring signals taking the mean value as a symmetrical line for the skewness of the monitoring signals acquired in a certain time period in the cutting process; x is the number ofKurReflecting the transient phenomenon and stationarity of the monitoring signal for the kurtosis of the monitoring signal acquired in a certain time period in the cutting process; f. ofiRepresenting the frequency spectrum, P (f), converted from a time-domain signal (i.e. the original signal) by a Fast Fourier Transform (FFT) of the acquired monitoring signal over a given time periodi) Representing the monitoring signalM represents the length of the power spectrum of the monitoring signal; x is the number ofFCTo monitor the frequency center of gravity of the signal, it is the static part of the frequency spectrum; x is the number ofFVThe sub-dynamic part of the spectrum, which is the frequency variance of the monitoring signal, reflects the degree of fluctuation of the spectrum of the monitoring signal near the center of gravity of the frequency.
Online prejudging: the extracted data features are taken as a vertical axis, time is taken as a horizontal axis, curves of time domain features and frequency domain features which are subjected to feature extraction and fusion and change along with time are displayed in real time, and if the curves exceed a threshold value in the machining process, an early warning is sent out, and the machine tool is stopped;
after the cleaning system cleans the cutter, the vision system detects the cutter grinding/damage in situ:
the soft robot drives the camera to collect complete images of the side edge and the bottom edge of the cutter, when the images of the side edge of the cutter are collected, the cutter needs to rotate for a circle and rotate for n times, the angle of 2 pi/n is rotated every time, n is greater than 2, so as to ensure that the images of the side edge of the cutter are completely shot, an image storage path is arranged in image collection software of the computer, the collected images are transmitted to an image collection card through a gigabit Ethernet cable and then transmitted to the computer, the robot drives the industrial camera to return to the original position after the collection is finished, and the electric window is closed;
and carrying out graying, noise reduction, median filtering, binarization processing and edge detection on the acquired cutter image by using image processing and analysis software to extract a cutter wear profile. Setting the pixel size of the image as M multiplied by N, calculating the actual area S and the side length a multiplied by b of a pixel on the calibrated image according to the optical magnification, measuring the grinding/damage area of the cutter, and calculating the grinding/damage area, the maximum grinding/damage belt width and the average grinding/damage belt width;
and judging the type of tool wear and tear and whether the tool needs to be replaced according to the tool wear amount and position detected at high precision.
In order to avoid the influence on the machining quality caused by the on-line prejudgment and the prejudgment error of the identification system and improve the detection efficiency, a frequency conversion detection method is adopted, namely, in the machining time period of the first 60% of the rated service life of the cutter in the actual machining initial stage of the machine tool, the on-site high-precision detection system can carry out on-site visual high-precision detection on the cutter before starting machining or after machining is finished every day, and after the on-line prejudgment and the identification system gives an alarm or in the machining time period of the last 40% of the rated service life of the cutter, the on-site high-precision detection system has frequent detection frequency and can carry out on-site visual high-precision detection before the beginning.
Claims (5)
1. A cutter damage on-line and on-line detection system in a clean cutting environment is characterized by comprising an on-line prejudging and identifying system, an on-line detection system, a data acquisition card (15), an image acquisition card (13), a cleaning system for cleaning a cutter and a computer (14);
the online prejudging and identifying system comprises a vibration sensor (1), a voltage sensor (2), a force sensor (3), a current sensor (4) and an acoustic emission sensor (5); the vibration sensor (1) is used for measuring the vibration quantity of a cutting position in the machining process of the machine tool in real time; the voltage sensor (2) and the current sensor (4) are respectively used for measuring the change values of the main shaft voltage and the current in the machining process of the machine tool in real time; the force sensor (3) is used for measuring the change value of the cutting force in the machining process of the machine tool in real time; the acoustic emission sensor (5) is used for measuring an acoustic signal of the cutter during cutting in real time;
the in-place detection system comprises a robot (78) and a vision system; the robot (78) is arranged on one side near the cutting position of the machine tool machining center; the vision system is arranged at the tail end of the robot (78), and the robot (78) drives the vision system to collect side edge images and bottom edge images of the cutter in place; the data acquisition card (15) and the image acquisition card (13) respectively transmit signals detected by the sensors and images acquired by the vision system to the computer (14).
2. Detection system according to claim 1, characterized in that the vision system (7) comprises a connection (75), a camera mount (74), an industrial camera (70), a lens (71), a ring light source (72); the camera support (74) is fixed at the execution end of the robot (78) through a connecting piece (75); the industrial camera (70) is fixed on a camera support (74); the lens (71) is connected with the industrial camera (70), and the annular light source (72) is arranged at the front end of the lens (71); the robot (78) drives the industrial camera (70) to collect the image of the cutter in place.
3. The detection system according to claim 1, characterized in that the cleaning system comprises an electrically powered window (9), a pneumatic cleaning high-pressure spray gun (11), an air compressor (10), a rubber hose with nozzle (12), a lens protection cover (73); the electric window (9) is arranged between the vision system and the prop; the pneumatic cleaning high-pressure spray gun (11) is connected to an air compressor (10), the rubber hose (12) is connected to the position of a spray gun port, and one end of a nozzle of the rubber hose (12) is fixed at the execution tail end of a robot (78) through a fixing frame (77); the lens protection cover (73) is arranged at the front end of the annular light source (72) and used for protecting the lens (71) and the annular light source (72).
4. A detection system according to claim 3, characterized in that the cleaning system further comprises a lens wiper (8), the lens wiper (8) comprises a lens wiper cotton (81) and a bracket (82), the lens wiper cotton (81) is fixed on the upper end of the bracket (82); when the lens (71) and the annular light source (72) are stained with dust or dirt, the robot (78) drives the camera lens (71) to wipe on the lens wiping cotton (81).
5. The inspection system of claim 1, wherein said robot (78) is a soft body robot.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN110340733A (en) * | 2019-07-19 | 2019-10-18 | 南京理工大学 | A kind of damage of Clean Cutting environment bottom tool online with in-place detection system and method |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN110340733A (en) * | 2019-07-19 | 2019-10-18 | 南京理工大学 | A kind of damage of Clean Cutting environment bottom tool online with in-place detection system and method |
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