CN213196754U

CN213196754U - Numerical control machine tool cutter state monitoring device based on vibration signal and image acquisition

Info

Publication number: CN213196754U
Application number: CN202020197014.8U
Authority: CN
Inventors: 尹硕; 李长河; 罗亮; 吉卫喜; 万斌辉; 李昊罡; 唐立志; 张彦彬; 徐海州; 杨敏; 洪华平; 徐杰; 刘明政; 高腾; 侯亚丽; 李润泽; 马五星; 陈帅
Original assignee: Jiangnan University; Qingdao University of Technology; Ningbo Sanhan Alloy Material Co Ltd
Current assignee: Jiangnan University; Qingdao University of Technology; Ningbo Sanhan Alloy Material Co Ltd
Priority date: 2020-02-21
Filing date: 2020-02-21
Publication date: 2021-05-14
Anticipated expiration: 2030-02-21

Abstract

The utility model discloses a digit control machine tool cutter state monitoring devices based on vibration signal and image acquisition, include: a vibration state detection device and a machine vision acquisition device; the vibration sensor acquires abnormal vibration signals in the cutter machining process in real time and transmits the abnormal vibration signals to the data analysis processing unit; the machine vision acquisition device comprises a camera, an X-axis displacement sensor, a Z-axis displacement sensor and a magnetic base; the camera rotating bracket fixing device is provided with a camera rotating bracket, the camera rotating bracket is provided with a camera, and the magnetic seat is detachably arranged and fixed on the working knife table. This openly adopts intelligent handle of a knife to carry out vibration signal's collection, increases machine vision monitoring module on this basis, and it can effectively guarantee the rate of accuracy as a direct monitoring mode.

Description

Numerical control machine tool cutter state monitoring device based on vibration signal and image acquisition

Technical Field

The utility model belongs to numerical control equipment state monitoring field especially relates to digit control machine tool cutter state monitoring devices based on vibration signal and image acquisition.

Background

The statements in this section merely provide background information related to the present disclosure and may not necessarily constitute prior art.

The machine tool is used as basic equipment in the manufacturing and processing industry, and has important significance for monitoring the state of the machine tool. In the numerical control machining process, the guarantee of product quality and the safety of the machining process do not leave the real-time monitoring of the numerical control equipment cutter, the state monitoring of the numerical control equipment cutter is an important component of the monitoring of the numerical control equipment, if the sudden condition of the cutter in the machining process cannot be monitored in real time and effective control measures cannot be taken, the influence of different degrees on the continuity of the machining process can be generated, and the immeasurable loss is caused to the whole manufacturing industry.

The related documents are consulted to find that abnormal damage of the equipment cutter in the machining process, namely the occurrence of cutter grinding and damage, can directly cause damage and scrapping of the machined parts if the abnormal equipment cutter is not controlled in time, and is particularly obvious in the machining process of the tool holder and the blade. In order to avoid the above situations, it is important to develop an effective tool state online monitoring and control system, which can effectively manage the tool, prolong the service life of the tool, reduce the production cost, improve the processing efficiency, and further increase the production benefits of enterprises.

Tool damage is the most common type of failure of machine tools during machining, and many machine tool manufacturers often design additional monitoring units during manufacturing, including monitoring of tool conditions. However, due to the fact that machining and manufacturing processes are varied, the selected tools are different, and therefore the adaptability and accuracy of the monitoring system of the device to tool monitoring are low.

The inventor finds that different types of sensors are added in the existing tool detection system in research, and the developed system needs to fuse a plurality of sensors, so that the stability of the working process of the system is reduced. Meanwhile, the sensor needs to be close to the cutter and a connecting piece nearby the cutter, and the sensor and a system processor need to be connected for data transmission, so that normal machining of a machine tool is disturbed to a great extent, and the application of the cutter state monitoring method in actual production is hindered.

SUMMERY OF THE UTILITY MODEL

For overcoming the not enough of above-mentioned prior art, the utility model provides a digit control machine tool cutter state monitoring devices based on vibration signal and image acquisition, the device with can realize the down time to the accurate monitoring of cutter state, the unusual diagnostic process of very big compression cutter, improve the production efficiency of lathe.

In order to achieve the above object, one or more embodiments of the present invention provide the following technical solutions:

digit control machine tool cutter state monitoring devices based on vibration signal and image acquisition includes: the data acquisition unit and the data analysis processing unit; the data acquisition unit comprises a vibration state detection device and a machine vision acquisition device;

the vibration state detection device comprises a vibration sensor and a wireless signal transmitting device which are arranged in the tool handle, wherein the vibration sensor acquires abnormal vibration signals in the machining process of the tool in real time and transmits the abnormal vibration signals to the data analysis processing unit;

the machine vision acquisition device comprises a camera, an X-axis displacement sensor, a Z-axis displacement sensor and a magnetic base;

the Z-axis displacement sensor is fixed on one side of the magnetic base through a Z-axis electric telescopic rod, the bottom side of the magnetic base is connected to an X-axis electric telescopic rod through a telescopic rod connecting component, the X-axis electric telescopic rod is connected with an X-axis displacement sensor, the X-axis electric telescopic rod is further connected to a camera rotating support fixing device, a camera rotating support is installed on the camera rotating support fixing device, a camera is installed on the camera rotating support, and the magnetic base is detachably installed and fixed on a working tool post.

According to the technical scheme, a roller installation box is further installed on one side of the magnetic seat and installed in a roller installation box fixing shell, a taper pin is arranged on the telescopic rod connecting part, the Z-axis displacement sensor and the Z-axis electric telescopic rod are fixedly installed through a Z-axis displacement sensor connecting plate, the X-axis displacement sensor and the X-axis electric telescopic rod are fixedly installed through an X-axis displacement sensor connecting plate, and one end of the X-axis electric telescopic rod is installed on the camera rotating support fixing device.

In a further technical scheme, the camera adopts a CCD camera, and the X-axis displacement sensor and the Z-axis displacement sensor adopt pull rope type displacement sensors.

According to a further technical scheme, a side wall threaded hole is formed in the side wall of the magnetic seat, a fixing groove is formed in the middle of the other side of the magnetic seat, and a magnetic seat knob is mounted at the top of the magnetic seat;

the conical pin hole has been seted up to the one end of the body of rod of Z axle electric telescopic handle, and the other end of the body of rod of Z axle electric telescopic handle is fixed boss, and the fixed connection of Z axle electric telescopic handle and magnetism seat is realized in the cooperation of fixed recess and fixed boss.

According to the further technical scheme, the X-axis displacement sensor connecting plate and the Z-axis displacement sensor connecting plate are of the same structure, and connecting plate through holes and stepped holes are formed in the plates respectively.

According to the further technical scheme, the bottom of the taper pin is provided with a taper pin dismounting threaded hole.

According to the technical scheme, one end of the X-axis electric telescopic rod is a telescopic rod connector, a fixed key groove is formed in the telescopic rod connector, and a connecting threaded hole is formed in a base of the other end of the X-axis electric telescopic rod.

According to the technical scheme, a camera support connecting threaded hole is formed in an upper supporting structure of the camera rotating support fixing device and used for being fixed with a camera, a connecting key groove through hole is formed in a middle supporting structure and used for being connected with a fixing key groove of an X-axis electric telescopic rod, and a sensor connector fixing threaded hole is formed in a bottom supporting structure.

According to the technical scheme, the camera rotating support is provided with a camera fixing buckle and a camera rotating driving device, and the camera rotating driving device is provided with a connecting threaded hole for being connected with the camera support connecting threaded hole to realize connection with the camera rotating support fixing device.

Further technical scheme, the handle of a knife includes handle of a knife fixed part, handle of a knife work portion and processing blade disc, is provided with handle of a knife junction beaded finish between handle of a knife fixed part, the handle of a knife work portion, and the handle of a knife junction beaded finish is fixed through beaded finish fixing bolt, beaded finish fixation nut, and the processing blade disc is installed on the blade disc installation department, and blade disc installation department and handle of a knife work portion threaded connection

In a further technical scheme, the data analysis processing unit is an industrial computer.

Further technical scheme, permanent magnet is installed to the handle of a knife, through the reduction gears who comprises rotatory rolling element and bearing, makes inside coil mechanism can generate electricity through the electromagnetic induction effect in the course of working, makes intelligent handle of a knife have from the power supply function, and wireless emitter is connected to inside integrated sensor simultaneously, has solved the line problem of walking of regional part circuit of processing, does not compress the normal operating space of lathe.

The above one or more technical solutions have the following beneficial effects:

this openly adopts intelligent handle of a knife to carry out vibration signal's collection, increases machine vision monitoring module on this basis, and it can effectively guarantee the rate of accuracy as a direct monitoring mode.

The utility model discloses the system can carry out real-time supervision to the lathe cutter in the numerical control equipment course of working, and when the cutter state takes place unusually, the lathe stops, and image vision system accomplishes the collection back of cutter image in the short time, carries out the tool changing, continues processing, guarantees the continuity of processing.

The data acquisition unit comprises an intelligent tool handle with a built-in sensor and a detachable machine vision acquisition device, wherein the detachable machine vision acquisition device is fixed on a machine tool through a magnetic base, the intelligent tool handle with the built-in sensor guarantees the accurate time point of the abnormity of a detection tool, and the machine vision acquisition device guarantees the accurate judgment of the state of the tool through image acquisition and information comparison of the tool.

The utility model discloses an adopt the CCD camera to carry out the collection of image among the machine vision device, can carry the CCD camera to the appointed detection position of system through two electric telescopic handle of perpendicular connection and accomplish image acquisition, the last displacement sensor that is equipped with of electric telescopic handle can monitor CCD camera position coordinate, makes CCD space coordinate can real-time supervision and control in the system.

The database unit is in communication connection with other units, so that data information of the units in the system can be shared in real time.

Various hardware devices in the system are high in matching degree with most of existing machine tools, installation is convenient, and machine tool equipment does not need to be transformed to a large extent.

Drawings

The accompanying drawings, which form a part of the specification, are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention without unduly limiting the scope of the invention.

FIG. 1 is a diagram of a system for detecting and controlling the on-line status of a tool according to an embodiment of the present disclosure;

FIG. 2 is an isometric view of a visual inspection device in accordance with an example embodiment of the present disclosure;

3(a) -3 (b) are perspective views of a magnetic base and a Z-axis electric telescopic rod of an embodiment of the disclosure;

fig. 3(c) is a fixed case of the camera data line retracting device according to the embodiment of the present disclosure;

fig. 4(a) is a connecting plate of a displacement sensor and a telescopic rod according to an embodiment of the disclosure;

FIG. 4(b) is a cross-sectional view of the connection plate A-A shown in FIG. 4(a) according to an embodiment of the present disclosure;

FIG. 5(a) is an assembly view of an electric telescopic rod, a connecting component and a sensor according to an embodiment of the present disclosure;

FIG. 5(B) is a cross-sectional view of the cross-section of FIG. 5(a) B-B in accordance with an embodiment of the present disclosure;

FIG. 5(c) is an enlarged partial view of i in FIG. 5(a) according to an embodiment of the present disclosure;

FIG. 6(a) is an isometric view of a telescoping rod connection member in an example embodiment of the present disclosure;

FIG. 6(b) is a front view of a telescoping rod connection component according to an embodiment of the disclosure;

FIG. 6(c) is an enlarged view of a portion of FIG. 6(b) ii according to an exemplary embodiment of the disclosure;

FIG. 6(d) is a cross-sectional view taken at C-C of FIG. 6(b) of an example embodiment of the present disclosure;

FIG. 7 is a taper pin according to an exemplary embodiment of the present disclosure;

FIG. 8 is an isometric view of an X-axis electric telescoping rod in accordance with an embodiment of the present disclosure;

fig. 9(a) is a camera rotating bracket fixing device according to an embodiment of the present disclosure;

fig. 9(b) is a top view of a camera rotating bracket fixing device according to an embodiment of the present disclosure;

FIG. 9(c) is an assembly view of the telescopic rod connecting device, the telescopic rod and the camera rotating bracket fixing device according to the embodiment of the present disclosure;

FIG. 9(d) is an enlarged partial view of FIG. 9(c) iii in accordance with an exemplary embodiment of the present disclosure;

fig. 10(a) is an isometric view of a camera rotating mount according to an example embodiment of the present disclosure;

FIG. 10(b) is an assembly view of a camera rotating bracket and a fixing device according to an embodiment of the present disclosure;

FIG. 11 is an exploded view of a camera data cable winding and unwinding device according to an exemplary embodiment of the present disclosure;

FIG. 12(a) is a housing of a camera data cable retracting device according to an embodiment of the present disclosure;

FIG. 12(b) is a lower case of the roller mounting case according to the embodiment of the present disclosure;

FIG. 12(c) is a top view of the lower case of the roller mounting case according to the embodiment of the present disclosure;

FIG. 12(D) is a cross-sectional view of the cross-section of FIG. 12(c) D-D in accordance with an embodiment of the present disclosure;

FIG. 13(a) is an isometric view of a roller mounting box according to an example embodiment of the present disclosure;

FIG. 13(b) is a perspective view of the upper case of the roller mounting case according to the embodiment of the present disclosure;

FIG. 13(c) is a perspective view of the lower housing of the roller mounting box according to the embodiment of the present disclosure;

FIG. 13(d) is a front view of a roller mounting case assembly according to an exemplary embodiment of the present disclosure;

FIG. 13(E) is a cross-sectional view taken along line E-E of FIG. 13(d) in accordance with an exemplary embodiment of the present disclosure;

FIG. 13(f) is a front view of a roller mounting case flange cover according to an exemplary embodiment of the present disclosure;

FIG. 13(g) is a cross-sectional view taken at section F-F of FIG. 13(F) of an example embodiment of the present disclosure;

FIG. 14(a) is a top view of an assembled roller unit according to an exemplary embodiment of the present disclosure;

FIG. 14(b) is a sectional view taken along line G-G of FIG. 14(a) in accordance with an exemplary embodiment of the present disclosure;

FIG. 15 is a perspective view of a roller drive motor according to an exemplary embodiment of the present disclosure;

FIG. 16(a) is a front view of a connection plate of the driving motor;

FIG. 16(b) is a cross-sectional view taken at H-H of FIG. 16(a) of an example embodiment of the present disclosure;

FIG. 16(c) is a partial enlarged view of iv in FIG. 16(a) according to an embodiment of the present disclosure;

fig. 16(d) is a schematic view illustrating a connection between a motor and a connection plate according to an embodiment of the present disclosure;

FIG. 16(e) is an enlarged view of a portion of an embodiment of the disclosure at v of FIG. 16 (d);

fig. 17(a) is an isometric view of an intelligent detection tool holder according to an embodiment of the disclosure;

FIG. 17(b) is an exploded view of the smart detection handle of the embodiment of the present disclosure;

FIGS. 18(a) and 18(b) are two tool head isometric views of replaceable installation of the intelligent tool head of the embodiment of the disclosure;

FIGS. 19(a) and 19(b) are isometric views of two indexable inserts according to embodiments of the present disclosure;

FIG. 19(c) is an isometric view of an insert cutting workpiece according to an example embodiment of the present disclosure;

FIG. 20(a) is a diagram of a structure of an internal component in the middle of an intelligent tool holder according to an embodiment of the present disclosure;

FIG. 20(b) is a front view of the middle of the intelligent tool handle of the embodiment of the disclosure;

FIG. 20(c) is a cross-sectional view taken along line I-I of FIG. 20(b) in accordance with an exemplary embodiment of the present disclosure;

FIG. 20(d) is a middle section view of an intelligent tool handle according to an embodiment of the disclosure

Fig. 21(a) is an isometric view of an internal coil of a power generation device according to an example embodiment of the present disclosure;

fig. 21(b) is a front view of a coil assembling unit of an embodiment of the present disclosure;

FIG. 21(c) is a cross-sectional view taken at J-J of FIG. 21(b) of an example embodiment of the present disclosure;

FIG. 21(d) is a partially enlarged view of vi in FIG. 21(b) according to an embodiment of the present disclosure;

fig. 22(a) is an isometric view of a vibration sensor unit of an example embodiment of the present disclosure;

FIG. 22(b) is a view showing a coil fixing bearing according to an embodiment of the present disclosure;

FIG. 23 is a schematic diagram illustrating the connection of various units in the system according to an exemplary embodiment of the present disclosure;

FIG. 24 is a flowchart illustrating operation of the machine tool after the tool is initially determined to be abnormal according to an embodiment of the present disclosure;

FIG. 25 is a schematic view of replaceable cutter insert wear in accordance with an embodiment of the present disclosure;

FIG. 26 is an isometric view of a tool changer of the numerical control apparatus according to an embodiment of the disclosure;

FIG. 27 is a schematic diagram of a tool initialization module in accordance with an exemplary embodiment of the present disclosure;

FIG. 28 is an isometric view of an intelligent tool magazine unit in accordance with an exemplary embodiment of the present disclosure;

in the figure, the device comprises a data acquisition unit I, a data analysis processing unit II, an intelligent tool magazine unit III, an abnormal tool conveying unit IV, an abnormal tool conveying unit V, a display unit VI, a decision and control unit VII and a database unit.

The camera comprises an I-01-magnetic base, an I-02-Z axis electric telescopic rod, an I-03-Z axis displacement sensor connecting plate, an I-04-Z axis displacement sensor, an I-05-roller mounting box, an I-06-roller mounting box fixing shell, an I-07-telescopic rod connecting part, an I-08-taper pin, an I-09-X axis electric telescopic rod, an I-10-X axis displacement sensor connecting plate, an I-11-X axis displacement sensor, an I-12-camera rotating bracket fixing device, an I-13-X axis telescopic rod end fixing nut, an I-14-X axis telescopic rod end fixing round head nut, an I-15-gasket, an I-16-CCD camera and an I-17-camera rotating bracket, wherein the I-01-magnetic base is arranged on the magnetic base;

the tool comprises an I-18-tool handle fixing part, an I-19-reinforcing ring fixing bolt, an I-20-tool handle joint reinforcing ring, an I-21-tool handle working part, an I-22-reinforcing ring fixing nut, an I-23-tool disc installation stop bolt, an I-24-tool disc installation stop block, an I-25-machining tool disc and an I-26-tool disc installation part.

I-0101-fixing groove, I-0102-side wall screw hole, I-0103-magnetic seat knob, I-0201-fixing boss, I-0202-first screw hole, I-0203-second screw hole, I-0204-conical pin hole, I-0601-horizontal side wall connecting through hole, I-0602-bottom plate connecting through hole, I-0603-vertical side wall connecting through hole, I-0301-connecting plate through hole, I-0302-stepped hole, I-0401-sensor connector, I-0201-telescopic link conical pin hole, I-0701-telescopic link part conical pin hole, I-0702-sensor connector fixing screw hole, I-0703-X axis telescopic link fixing hole, i-0801-taper pin disassembly threaded hole, I-0901-telescopic rod connector, I-0902 fixing key slot, I-0903-connecting threaded hole, I-1201-camera support connecting threaded hole, I-1202-connecting key slot through hole, I-1203-sensor connector fixing threaded hole, I-1701-camera fixing buckle, I-1702-camera rotation driving device and I-1703-connecting threaded hole;

i-0501-roller box top plate, I-0502-flange cover connecting and fixing bolt, I-0503-coupling connecting nut, I-0504-coupling, I-0505-flat key, I-0506-top plate connecting bolt, I-0507-coupling connecting bolt, I-0508-roller driving stepping motor, I-0509-motor fixing bolt, I-0510-spacer, I-0511-coupling bolt spacer, I-0512-motor fixing plate, I-0513-roller main box, I-0514-roller main box part connecting bolt, I-0515-hexagon nut, I-0516-spacer, I-0517-roller box lower shell, I-0518-roller box upper and lower shells connecting nut, i-0519-a winding roller, I-0520-a deep groove ball bearing, I-0521-a bearing sleeve, I-0522-an upper shell of a roller box body, I-0523-an upper shell and a lower shell of the roller box body are connected with bolts, and I-0524-an end cover of the roller box body;

i-051301-roller box lower shell connecting through hole, I-050101-image signal data line hole, I-050102-roller driving motor power supply line hole, I-051201-driving motor connecting plate fixing hole, I-051301-roller box lower shell stepped hole, I-052201-roller box upper shell side wall threaded hole, I-052202-upper and lower shell connecting through hole, I-050801-driving motor fixing threaded hole, I-051201-connecting plate fixing motor connecting hole, I-051202-connecting plate and lower shell connecting through hole;

i-2101-radio frequency device, I-2102-radio frequency device fixing frame, I-2103-fixing frame assembling bearing, I-2104-coil upper end supporting bearing, I-2105-rotary rolling element upper end supporting bearing, I-2106-power supply module, I-2107-rotary rolling element, I-2108-rotary rolling element lower end supporting bearing, I-2109-flange cover, I-2115-signal transmitting hole, I-2116-sensor data line hole, I-211001-coil winding boss, I-210401-power supply electricity storage module, I-210402-power supply rectification module, I-211002-electric wire conveying pipe, I-2112-middle shaft transmission line pipe and I-2113-vibration sensor, i-2114-vibration sensor fixing clamp, I-211401-fixing clamp positioning hole, I-211402-data line hole, I-2111-coil fixing bearing, I-211101-fixing clamp positioning threaded hole, I-211102-coil fixing groove, I-211103-sensor fixing hole, I-211104-bearing rolling body and support and I-211105-bearing bottom outer ring.

III-01-intelligent tool magazine fixing hole, III-02-tool sleeve, III-03-tool magazine tool changing edge, III-04-tool magazine tool changing driving device, III-05-tool magazine fixing frame, III-06 tool changing fixing platform, III-07-tool changing rotating shaft and III-08-tool changing gripper.

Detailed Description

It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments in accordance with the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.

In the case of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other.

Example one

Referring to the attached drawing 1, the embodiment discloses a numerical control machine tool cutter state monitoring and control system, which comprises a data acquisition unit I, a data analysis processing unit II, a VII database unit, a VI decision and control unit, an intelligent tool magazine unit III, a display unit V and an abnormal cutter conveying unit IV. The system can realize accurate judgment of the cutter state through the data acquisition and data analysis processing unit, and the intelligent tool magazine unit and the decision and control unit realize replacement of a new cutter under the abnormal condition of the machine tool cutter, accurate judgment and classification of an abnormal cutter and subsequent intelligent processing.

In one embodiment, fig. 23 is a schematic diagram of the connection of the units of the system; the data acquisition unit comprises a power sensor, a data acquisition card, an industrial CCD camera and an AD converter, data acquisition is completed and is transmitted to the data analysis and processing unit, the data analysis and processing unit comprises an industrial computer and a software processing module operated by the industrial computer, the data analysis and processing unit is communicated with the decision and control unit, the decision and control unit comprises an industrial computer central processing unit and a numerical control machine control system, the decision and control unit is communicated with the intelligent tool magazine unit, the intelligent tool magazine unit comprises a disc-type tool magazine, a tool changer and a tool magazine intelligent module, the auxiliary equipment is an industrial mechanical gripper, and the intelligent tool magazine unit, the decision and control unit, the data analysis and processing unit and the database server are respectively communicated with the display unit to display required data.

In a specific embodiment, the data acquisition unit structure and the connection mode of the components are as follows: the data acquisition unit I is divided into two parts, including vibration state detection device and visual detection device, and the visual detection device main part comprises electric telescopic handle and stay cord formula displacement sensor, assembles detachable external image visual acquisition device through other auxiliary device.

The visual detection device is realized as shown in the attached figure 2, and comprises a camera, an X-axis displacement sensor I-11, a Z-axis displacement sensor I-04 and a magnetic seat I-01;

the Z-axis displacement sensor I-04 is fixed on one side of the magnetic base through a Z-axis electric telescopic rod I-02, the bottom side of the magnetic base is connected to an X-axis electric telescopic rod through a telescopic rod connecting part I-07, the X-axis electric telescopic rod is connected with an X-axis displacement sensor, the X-axis electric telescopic rod is further connected to a camera rotating support fixing device, a camera rotating support is installed on the camera rotating support fixing device I-12, a camera is installed on the camera rotating support I-17, and the magnetic base is installed and fixed on the working tool table.

The roller mounting box is mounted on one side of the magnetic base and is mounted in a roller mounting box fixing shell I-06, a taper pin I-08 is arranged on a telescopic rod connecting part, a Z-axis displacement sensor and a Z-axis electric telescopic rod are fixedly mounted through a Z-axis displacement sensor connecting plate I-03 through bolts, an X-axis displacement sensor and an X-axis electric telescopic rod I-09 are fixedly mounted through an X-axis displacement sensor connecting plate I-10 through bolts, and one end of the X-axis electric telescopic rod is mounted on a camera rotating support fixing device through an X-axis telescopic rod end fixing round-head nut I-13, an X-axis telescopic rod end fixing nut I-14 and a gasket I-15.

In one embodiment, the camera is a CCD camera I-16, and the X-axis displacement sensor and the Z-axis displacement sensor are pull-rope type displacement sensors.

In the specific implementation example, the drawing of the shaft of the magnetic base and the Z-axis electric telescopic rod is shown in the attached figures 3(a) and 3(b), in the figure 3(a), a side wall threaded hole I-0102 is formed in the side wall of the magnetic base I-01, a fixing groove I-0101 is formed in the middle of the other side of the magnetic base, a magnetic base knob I-0103 is installed at the top of the magnetic base,

in fig. 3(b), one end of the rod body of the Z-axis electric telescopic rod is provided with a conical pin hole i-0204, the other end of the rod body of the Z-axis electric telescopic rod is provided with a fixed boss, and two side surfaces of the fixed boss are respectively provided with a first threaded hole i-0202 and a second threaded hole i-0203.

In the specific embodiment, fig. 3(c) is a schematic structural diagram of a fixed case of the data cable winding and unwinding device of a camera, wherein a bottom plate connecting through hole i-0602 is formed on the upper bottom plate of the case, a vertical side wall connecting through hole i-0603 is formed on the vertical side wall, and the upper edge of the other vertical side wall extends outwards and horizontally to form a horizontal side wall and is provided with a horizontal side wall connecting through hole i-0601.

In a specific embodiment, fig. 4(a) is a structural diagram of a displacement sensor and a connecting plate of an expansion link; FIG. 4(b) is a cross-sectional view of the web A-A shown in FIG. 4 (a);

the X-axis displacement sensor connecting plate and the Z-axis displacement sensor connecting plate are of the same structure, and are respectively provided with connecting plate through holes I-0301 and step holes I-0302, in an implementation example, the number of the step holes is 4, the step holes are located in the middle of the connecting plate, the number of the connecting plate through holes is 4, and the two connecting plate through holes are in a group and are respectively located on the structures, close to the two ends, of the connecting plate.

The main body part of the displacement sensor is fixed on the driving equipment of the electric telescopic rod, and the other end of the displacement sensor is fixed at the tail end of the telescopic rod. The CCD camera is connected with the tail end of the X-axis electric telescopic rod through a rotary controller, rotation in the Y-axis direction can be achieved, and effective collection of a cutter image can be achieved by matching with linear displacement of the X axis and the Y axis.

In the specific embodiment, fig. 5(a) is an assembly diagram of the electric telescopic rod, the connecting component and the sensor; FIG. 5(B) is a cross-sectional view of the cross-section B-B of FIG. 5 (a); FIG. 5(c) is an enlarged partial view of i in FIG. 5 (a);

a telescopic rod conical pin hole I-0204 formed in the telescopic rod connecting part I-07 is matched with a telescopic rod linking part I-07 conical pin positioning hole I-0701, a sensor connector fixing threaded hole I-0702 is further formed in the telescopic rod connecting part I-07 and used for fixing a sensor, and a sensor connector I-0401 is arranged at the lower end of a Z-axis displacement sensor I-04.

In a specific embodiment, fig. 6(a) is an axonometric view of the connecting part of the telescopic rod; FIG. 6(b) is a front view of the connecting part of the telescopic rod; FIG. 6(c) is an enlarged view of a portion of FIG. 6(b) ii; FIG. 6(d) is a cross-sectional view taken along line C-C of FIG. 6 (b);

an X-axis telescopic rod fixing hole I-0703 is formed in the side wall of the end base of the telescopic rod connecting part I-07.

In a specific embodiment, fig. 7 shows a taper pin structure, and a taper pin dismounting threaded hole i-0801 is formed in the bottom of the taper pin.

FIG. 8 is an isometric view of the X-axis electric telescoping rod; one end of the X-axis electric telescopic rod is a telescopic rod connector I-0901, a fixed key groove I-0902 is formed in the telescopic rod connector, and a connecting threaded hole I-0903 is formed in a base at the other end of the X-axis electric telescopic rod.

FIG. 9(a) shows a camera rotating holder fixture; FIG. 9(b) is a top view of the camera rotating bracket fixture; FIG. 9(c) is an assembly view of the telescoping rod connection device, telescoping rod and camera rotating bracket fixture; FIG. 9(d) is a partial enlarged view of iii in FIG. 9 (c);

a camera support connecting threaded hole I-1201 is formed in an upper supporting structure of the camera rotating support fixing device and used for being fixed with a camera, a connecting key groove through hole I-1202 is formed in a middle supporting structure and used for being connected with an X-axis electric telescopic rod fixing key groove, and a sensor connector fixing threaded hole I-1203 is formed in a bottom supporting structure.

FIG. 10(a) is an isometric view of a camera rotating mount; FIG. 10(b) is an assembly view of the camera rotating bracket and the fixing device; the camera rotating bracket is provided with a camera fixing buckle I-1701 and a camera rotating driving device I-1702, and the camera rotating driving device is provided with a connecting threaded hole I-1703 which is used for being matched with the camera bracket connecting threaded hole I-1201 to realize the connection with the camera rotating bracket fixing device.

FIG. 11 is an exploded view of the camera data cord retracting device; the camera data line winding and unwinding device comprises a roller main box body I-0513, a roller box body top plate I-0501 is arranged on the roller main box body, the roller box body top plate is fixed on the roller main box body through a top plate connecting bolt I-0506, and the roller main box body is fixed through a roller main box body part connecting bolt I-0514.

Bearing sleeve I-0521, deep groove ball bearing I-0520, winding roller I-0519, roller box end cover I-0524, flange cover connecting and fixing bolt I-0502, coupling connecting nut I-0503, coupling I-0504, coupling I-0511-coupling bolt gasket, flat key I-0505, coupling connecting bolt I-0507 and roller driving stepping motor are matched and connected in sequence, the roller driving stepping motor I-0508 is fixed on the motor fixing plate I-0512 by a motor fixing bolt I-0509 and a gasket I-0510, the lower roller box shell I-0517 and the upper roller box shell I-0522 are fixedly connected through an upper roller box shell and lower roller box shell connecting nut I-0518, an upper roller box shell and lower roller box shell connecting bolt I-0523, a hexagon nut I-0515 and a gasket I-0516.

FIG. 12(a) is a camera data cord retraction device housing; FIG. 12(b) shows a lower case of the roller mounting case; FIG. 12(c) is a top view of the lower housing of the roller mounting box; FIG. 12(D) is a cross-sectional view taken along line D-D of FIG. 12 (c);

the roller main box body is provided with a roller box body lower shell connecting through hole I-051301, an image signal data line hole I-050101, a roller driving motor power line hole I-050102, a driving motor connecting plate fixing hole I-051201 and a roller box body lower shell stepped hole I-051301.

FIG. 13(a) is an isometric view of a roller mounting box; FIG. 13(b) is an isometric view of the upper housing of the roller mounting case; FIG. 13(c) is a perspective view of the lower housing of the roller mounting box; FIG. 13(d) is a front view of the roller mounting box assembly; FIG. 13(E) is a cross-sectional view taken along line E-E of FIG. 13 (d); FIG. 13(f) is a front view of a roller mounting housing flange cover; FIG. 13(g) is a cross-sectional view taken along line F-F of FIG. 13 (F);

the roller mounting box upper box body is provided with roller box body upper shell side wall threaded holes I-052201 and upper and lower shell connecting through holes I-052202.

The lower shell of the roller box body is provided with an upper shell connecting through hole 1I-051701, a lower shell connecting through hole I-051702, a flange cover connecting threaded hole I-051702 and a roller box body lower shell and roller main box body connecting through hole I-051703.

The upper shell connecting through hole 1I-051701 and the lower shell connecting through hole 2I-052202 are matched with mounting bolts to realize the roller mounting box.

FIG. 14(a) is a top view of the roller unit assembly; FIG. 14(b) is a sectional view taken along line G-G of FIG. 14 (a);

when the roller unit is assembled, the outer ring I-052001 of the deep groove ball bearing, the inner ring I-052002 of the deep groove ball bearing, the flange cover connecting positioning hole I-052401 and the flange cover inner top ring I-052402 are used for positioning and assembling.

FIG. 15 is a perspective view of a roller drive motor shaft; a connecting plate fixing motor connecting hole I-051201, a connecting plate and a lower shell connecting through hole I-051202 are formed in the motor fixing plate, and the roller driving stepping motor is installed on the motor fixing plate through a driving motor fixing threaded hole.

FIG. 16(a) is a front view of a connection plate of the driving motor; FIG. 16(b) is a sectional view taken along line H-H in FIG. 16 (a); FIG. 16(c) is a partially enlarged view of iv in FIG. 16 (a); FIG. 16(d) is a schematic view of the connection between the motor and the connecting plate; fig. 16(e) is a partially enlarged view taken at v in fig. 16 (d).

FIG. 17(a) is an isometric view of an intelligent detection tool holder; FIG. 17(b) is an exploded view of the smart detection handle; the knife handle comprises a knife handle fixing part I-18, a knife handle working part and a processing knife disk. A cutter handle joint reinforcing ring is arranged between the cutter handle fixing part and the cutter handle working part, the cutter handle joint reinforcing ring I-20 is fixed through a reinforcing ring fixing bolt I-19 and a reinforcing ring fixing nut I-22, a cutter head mounting stop bolt I-23 and a cutter head mounting stop block I-24 are arranged between the cutter handle working part I-21 and a machining cutter head, the machining cutter head I-25 is mounted on a cutter head mounting part I-26, and the cutter head mounting part is in threaded connection with the cutter handle working part.

Fig. 18(a) is an isometric view of a side milling cutter head, and fig. 18(b) is an isometric view of a face milling cutter head; fig. 19(a) is an isometric view of a face milling indexable insert; figure 19(b) is an isometric view of a replaceable insert for a grooving tool; fig. 19(c) is an isometric view of the insert cutting workpiece.

FIG. 20(a) is a structural diagram of internal components in the middle of the intelligent knife handle, and FIG. 20(b) is a front view of the middle of the intelligent knife handle; FIG. 20(c) is a cross-sectional view taken along line I-I of FIG. 20 (b); fig. 20(d) is a middle sectional view of the intelligent tool handle.

The intelligent knife handle is internally provided with a radio frequency device I-2101, a radio frequency device fixing frame I-2102, a fixing frame assembling bearing I-2103, a coil upper end supporting bearing I-2104, a rotating rolling body upper end supporting bearing I-2105, a power supply module I-2106, a rotating rolling body I-2107, a rotating rolling body lower end supporting bearing I-2108 and a flange cover I-2109 in sequence, and the components are sequentially assembled and installed inside the intelligent knife handle.

A signal transmitting hole I-2115 and a sensor data line hole I-2116 are formed in a handle shell of the intelligent handle.

FIG. 21(a) is an isometric view of an internal coil of a power plant; fig. 21(b) is a front view of the coil assembly unit; FIG. 21(c) is a sectional view taken along line J-J of FIG. 21 (b); FIG. 21(d) is a partially enlarged view of vi in FIG. 21 (b).

The power generation device comprises coil winding bosses I-211001;

a power storage module I-210401, a power rectification module I-210402, a wire conveying pipe I-211002, a vibration sensor fixing clamp I-2114, a vibration sensor I-2113 and a reversing bearing I-2111 are respectively arranged on a supporting bearing at the upper end of the coil.

Fig. 22(a) is an isometric view of a vibration sensor unit; internal coil of power generation device: the device comprises a data wire hole I-211402, a vibration sensor I-2113, a fixing clamp positioning hole I-211401 and a middle shaft transmission wire tube I-2112; the data wire hole I-211402 is kept on the same axis through the middle shaft transmission wire tube I-2112, and the bolt fixes the vibration sensor through the fixing clamp positioning hole I-211401.

FIG. 22(b) coil fixing bearing; the coil assembly unit includes: the sensor comprises a fixing clamp positioning threaded hole I-211101, a coil fixing groove I-211102, a sensor fixing hole I-211103, a bearing rolling body and support I-211104 and a bearing bottom outer ring I-211105. The sensor is tightly fixed on the coil unit through the fixing clamp positioning threaded hole I-211101 and the fixing clamp positioning hole I-211401 through bolts. The vibration sensor I-2113 is arranged in the sensor fixing hole I-211103 to be positioned and fixed by an adhesive, and effective transmission of a tool vibration signal is guaranteed.

FIG. 26 is an isometric view of a tool changer of the numerical control apparatus; the tool changing device of the numerical control equipment comprises a tool changing fixing platform III-06 and a tool changing clamping hand III-08, wherein the tool changing fixing platform III-06 and the tool changing clamping hand III-08 are connected through a tool changing rotating shaft III-07.

FIG. 28 is an isometric view of the smart tool magazine unit; the intelligent tool magazine unit comprises a tool magazine fixing frame III-05, a tool sleeve III-02 is arranged in the tool magazine fixing frame, a tool changing port III-03 of the tool magazine is arranged at the bottom of the tool magazine fixing frame, an intelligent tool magazine fixing hole III-01 is formed in the tool magazine fixing frame, and a tool magazine tool changing driving device III-04 is further arranged on the tool magazine fixing frame.

In a specific implementation example, a side wall of the magnetic seat I-01 is provided with a side wall threaded hole I-0102 which is matched with a horizontal side wall connecting through hole I-0601 on the roller mounting box fixing shell for mounting a fixing bolt, and meanwhile, a second threaded blind hole I-0203 on the Z-axis electric telescopic rod and a vertical side wall connecting through hole I-0603 are provided with fixing bolts, so that the roller mounting box I-05 can be mounted in the fixing shell to be in a designated working position through connection of the two positions. The magnetic seat is installed with Z axle electric telescopic handle through the cooperation of fixed recess I-0101 and fixed boss I-0201, relies on gravity etc. to accomplish the axial fixity installation of telescopic link, has realized through above connected mode that it is convenient to dismantle, is convenient for damage the part to the device and changes, has improved the life of device to make its installation easy operation. The Z-axis displacement sensor and the electric telescopic rod are fixedly installed through a Z-axis displacement sensor connecting plate I-03 by means of bolts, a common bolt fixes the connecting plate on the electric telescopic rod through a connecting plate through hole I-0301, the displacement sensor is fixed through a countersunk screw penetrating through a connecting plate step hole I-0302, an assembly drawing is shown in an electric telescopic rod (a) in fig. 5, a connecting part and a sensor assembly drawing are shown, the fixed sensor connector I-0401 and a connector threaded hole in a telescopic rod connecting part I-07 are kept on the same axis, a connected pull rope is kept perpendicular to a horizontal plane, and the installation mode guarantees the accuracy of the vertical displacement of a measuring camera.

Similarly, the connection mode of the X-axis pull rope type displacement sensor and the telescopic rod is the same as that of the method, and the X-axis displacement sensor connector is fixed at the I-1203 position of the fixing threaded hole of the I-12 sensor connector of the camera rotating bracket fixing device in the same connection mode, so that the pull rope direction of the X-axis sensor is parallel to the horizontal plane, and the accuracy of measuring the horizontal displacement of the camera is ensured. The linear movement of the camera in two directions is completed through two electric telescopic rods, the two telescopic rods are connected through a telescopic rod connecting part I-07, a Z-axis telescopic rod is connected with a threaded hole in the connecting part through threads at the bottom end of a rod part, the cross section of threaded connection is shown as the cross section of a B-B section in a part (a) in a part (B) in a figure 5, and is locked through a conical pin I-08, so that the bad conditions such as looseness and the like between the parts in reciprocating linear motion are avoided, an X-axis electric telescopic rod penetrates through an X-axis telescopic rod fixing hole I-0703 through a bolt to be fixed at the threaded hole I-0903, and the front end face and the rear end face are connected through. A key groove I-0902 is formed in a threaded rod I-0901 at the tail end of the X-axis electric telescopic rod, the installed camera rotating bracket fixing device I-12 is circumferentially positioned through an installation flat key, meanwhile, the camera rotating bracket fixing device I-12 is axially positioned through a v-shaped gasket I-15, a fixing nut I-13 and a round-head nut I-14, and the double-nut fastening structure is adopted, so that the anti-loosening effect can be achieved to a great extent. The camera rotating bracket fixing device is connected with the camera part and the translation device part.

The assembly view of the whole X-axis and direct connection part is shown in FIG. 9(c) the assembly view of the telescopic rod connection device, the telescopic rod and the camera rotating bracket fixing device. The camera rotating bracket I-17 is fixed on the camera rotating bracket fixing device I-12 through a countersunk screw I-1201, as shown in an assembly drawing of the camera rotating bracket and the fixing device in fig. 10 (b). The camera support rotating device I-1702 is internally provided with a stepping motor and a control unit which drive a camera to rotate around the Y axis of the machine tool according to a specified angle, and the image acquisition of a specific angle can be realized in the mounting mode and the component structure. Camera support buckle I-1701 makes things convenient for the dismantlement of CCD camera to change, satisfies the system and changes the camera according to different functional requirements.

The roller part of the vision system mainly meets the requirements of adjusting the dynamic lengths of a camera data line, a motor power line and the like in the motion process of the telescopic rod, and the motion process is elaborated in the camera motion function design below. All the components are integrally installed in a roller installation box I-05, the main structure is that a stepping motor I-0508 connected with a control unit drives a roller I-0519, the control unit controls the stepping motor to rotate corresponding to the revolution according to the length of a system command line, a wire harness is wound in a roller rolling groove, the winding and unwinding of the wire harness are realized through the positive and negative rotation of the motor, a winding roller I-0519 is installed in a lower shell of a roller box body I-0517, the lower shell is positioned and installed through a positioning through hole and a box body stepped hole I-051201, a countersunk head bolt I-0514, a nut I-0515 and a gasket I-0516 are connected through bolts, a driving motor is arranged on a motor connecting plate in a similar mode, the motor connecting plate is also installed and fixed on a roller main box body according to a bolt connection mode, the axial line coincidence of the roller and a motor spindle is ensured, and the two shafts, so that the motor can drive the roller to rotate. The idler wheel I-0519 is placed in the idler wheel box body, the box body is divided into an upper part and a lower part, a cavity with a specific structure is cast inside, the assembly of the idler wheel is completed by matching a bearing sleeve I-0521, a deep groove ball bearing I-0521, an end flange cover I-0524 and the cavity with the specific structure, the assembled section is shown as a section view of a G-G section in a figure 14(a) in a figure 14(b), and finally the upper shell and the lower shell of the idler wheel box body and the flange cover are connected through bolts at specific positions and packaged in the whole structure.

In a specific implementation example, the vibration signal acquisition is completed by the intelligent knife handle, the vibration sensor is arranged in the intelligent knife handle, the self-power generation of the intelligent knife handle in the machining process is realized through the rotary driving mechanism, and the vibration signal is supplied to the vibration sensor and the top wireless signal transmitting device for use. The intelligent knife handle main body is composed of a knife handle fixing part I-18 and a knife head fixing part I-21 of a knife handle core working part I-26. The core working part I-19 of the tool handle is a hollow part, various working parts are integrated inside the hollow part, threaded holes are formed in the upper port and the lower port of the hollow part, threads are machined in the upper part and the lower part of the tool handle, and the three parts are integrally connected through threaded connection. In order to ensure the overall strength of the tool handle, the threaded connection part is fixed by the I-20 tool handle reinforcing ring, so that the tool handle has enough deformation resistance strength in the machining process. The cutter head is used for mounting various blades, different cutter heads can be replaced according to different machining processes, for example, two different cutter heads are shown in fig. 18, different cutter heads can be mounted with different types of blades, and as shown in indexable blade axonometric diagrams in fig. 19(a) and 19(b), the function of monitoring various mounted different blades by the system is realized.

The power generation device is arranged in the working part I-21 of the tool handle, the power generation principle is an electromagnetic induction principle, the tool handle rotates at a high speed in the machining process to drive the rolling body I-2107 of the internal power generation device to rotate along with the tool handle, the following rotation mainly acts through the friction force between the cylindrical rolling body and the inner wall of the working part, the rolling body I-2107 is in an axonometric view as shown in the structure diagram of an internal part in the middle of the intelligent tool handle in fig. 20(a), the top and the bottom of the rolling body adopt a bearing as shown in the front view in the middle of the intelligent tool handle in fig. 22(b), the bearing rolling body and the retainer I-211104 are shown as corresponding parts in the front view in the middle of the intelligent tool handle in fig. The inner ring and the outer ring can rotate relatively under the action of the rolling bodies. This type of bearing is used for all bearings in the power plant. The rolling body and the bearings at two ends are installed in the hollow part of the working part of the tool handle, the rolling body is packaged in a hollow cavity of the working part through a flange cover at the bottom, a coil is installed in the rotary rolling body I-2107, the coil is illustrated in an axonometric view of an internal coil of a power generation device in fig. 21(a), the coil is fixed on a speed reduction bearing installed on a closed entity at the lower end of the rotary rolling body, the outer ring of the bottom of the speed reduction bearing is in transition fit with the closed entity, the shape of a groove of the speed reduction bearing I-211102 is the same as that of. The tool holder rotates at a high speed to drive the rotary rolling body to rotate along with the tool holder, the rotary rolling body drives the outer ring at the bottom of the reduction bearing to rotate, the inner ring at the top of the reduction bearing also rotates along with the tool holder under the action of the friction force of the rolling body, after passing through the mechanism, the tool shank rotates at a high speed, but the inner coil rotates along with the tool shank at a very slow speed, the tool shank and the inner coil generate a large slip ratio, the permanent magnet is arranged in the hollow part of the knife handle, the coil part is integrated with the closed coil, the closed coil cuts the magnetic induction line due to the changing magnetic field generated by the rotation of the permanent magnet in the rotating state to generate current, the current generated by the closed coil flows through a cross section of 21(b) J-J in figure 21(c), the current conveying part I-211002 is conveyed to the current rectifying module I-210402 to be rectified and then stored in the power storage module I-210401, and power is supplied to the vibration sensor and the wireless radio frequency transmitting device through the power line through the internal power supply pipeline. The magnetic field shielding plate made of specific materials is arranged between the power generation device and the upper wireless signal transmitting device and is used for shielding the magnetic field interference of the magnetic field of the power generation device to the wireless radio frequency device in the signal transmission process. The coil internal integrated vibration sensor is fixed on the speed reduction bearing through a fixing frame I-2114 and used for acquiring vibration signals generated in real time due to cutter change in the machining process, and the assembly cross section of a coil internal integrated component is shown as a front view of a coil assembly unit 21(b) in fig. 21 (c).

All units communicate through the intelligent modules to achieve information intercommunication, and then the master control system is enabled to sequence the actions in priority in different stages, so that normal operation of the machine tool is guaranteed. As shown in the working flow chart of the machine tool after the tool is initially judged to be abnormal in fig. 24, when the state of the tool of the machine tool is abnormal, the machine vision system is connected with the servo system of the machine tool, the servo system receives an action instruction of the machine vision system, and after the acquisition of images is completed in cooperation with the machine vision system, the connection is disconnected, and the normal machining of the machine tool is recovered. Meanwhile, the processing parameters of each unit can be acquired in real time, so that each part can complete set work according to processing requirements. If the machining precision is input into the system, the cutter monitoring unit acquires the machining precision in real time, and the cutter abnormity pre-judgment threshold value is changed in real time, so that the cutter of the machine tool can be always in an effective state.

The system core operation part is executed by an external industrial computer, and comprises real-time acquisition and analysis judgment decision of real-time data of each subsystem, command transmission and transmission to each subsystem aiming at different working conditions, execution of actions of each machine tool at different stages, coordination and distribution of subsystem work and the like.

The database unit VII is used for storing mass data generated in the intelligent monitoring process, signal data are stored and transmitted with the system mainly aiming at vibration signals acquired in the cutter monitoring process and image signals acquired by machine vision, meanwhile, the database in the unit simultaneously completes design and process parameters in the machining of the numerical control machine tool, and the data are in a dynamic mode under most conditions and need to be randomly stored in the design and manufacturing process. The function requirement finally realized by the system is that besides real-time display is carried out on a display interface, related manufacturing and enterprise management personnel can inquire the information of the numerical control equipment in real time at any time, so that the system selects a Web database system based on a C/S structure as a main working carrier of a database unit, data input and storage and data output are realized through communication connection with the whole system, the Web database system becomes a transfer station for running of each system, the memory load of an industrial computer is greatly saved, the normal and stable running of the system is guaranteed, and meanwhile, the real-time acquisition of the equipment information can be realized through intelligent equipment such as a mobile phone and the like by the related personnel through a Web client. Because the modern database has comprehensive data center processing capability, rapid performance and unlimited virtualization capability, the database in the system can complete the functions of the database of the system and simultaneously meet the functional requirements of data storage of other systems of the numerical control equipment, namely the module has the extensible capability in practical application.

And the decision and control unit VI mainly comprises an external industrial computer and an internal control system of the numerical control equipment. When the internal processor of the professional computer carries out intelligent analysis on the acquired data to obtain a decision, and then different actions are completed by giving instructions to the machine tool control system.

And the intelligent tool magazine unit II is developed based on an ARM microprocessor. An automatic tool changing system is designed, and automatic tool changing action can be carried out according to a tool changing instruction of a machine tool. In the embodiment, the function introduction of the tool magazine is carried out by taking the disc-shaped tool magazine as an example, different types of tools used in the machining process are backed up and installed in the disc-shaped tool magazine, and two tools of the same type are installed nearby, so that the tool management is facilitated. The tool selection mode adopts any tool selection mode, and the required tools are selected according to the requirements of the program instructions, namely when the tools in the machining process are abnormal, the spare tools are appointed to be selected from the tool magazine for replacement according to the program tool changing instructions sent by the decision unit. And a tool identification device is arranged in an automatic tool changing system in the intelligent tool magazine unit. The identification of the tool is mainly performed by numbering the different tool holders in the tool magazine, which are fitted with different types of tools and fed into the ARM tool changing system before machining. The intelligent tool magazine can be used for calibrating the state of the tool after the state of the tool is identified according to the data analysis module. And when the data analysis unit analyzes that the cutter is abnormal, the unit carries out abnormal calibration on the number of the cutter seat where the cutter is located, the cutter is replaced, and the abnormal cutter is put into a warehouse. And when the image signal data is analyzed to obtain the accurate state of the cutter, transmitting the accurate state of the cutter to the intelligent tool magazine unit to update the information of the abnormal state. When the tool state pre-judging module is judged to be misjudged, the information is transmitted to the intelligent tool magazine unit to perform abnormal calibration removal on the tool with abnormal calibration.

The tool changing device of the unit is composed of two manipulator devices with opposite directions, and the replacement of the tool between the tool magazine and the workbench is completed through the directional rotation of the driving device to the rotating shaft.

The abnormal cutter conveying unit IV mainly refers to an industrial mechanical gripper, such as an ABB industrial robot and other equipment. The mutual transmission and sharing of information are realized by establishing communication connection between the industrial robot and the intelligent tool magazine, and the auxiliary equipment is guided to complete set work. The specific work is as follows: after the intelligent tool magazine updates the accurate state of the calibrated abnormal tool, the manipulator classifies and conveys the abnormal tool to a tool processing area according to the abnormal types of different tools, and if the cutting edge of the tool is damaged, the tool is conveyed to a tool changing area; delivering the knife to the knife sharpening area when the knife edge becomes dull, etc.

Example two

The embodiment discloses a method for monitoring and controlling the state of a cutter of a numerical control machine tool, and a working flow chart of the machine tool after the cutter is judged to be abnormal for the first time is shown in figure 24; FIG. 25 is a schematic view of replaceable cutter insert wear; FIG. 27 is a schematic diagram of a tool initial determination module; the method comprises the following steps:

the data acquisition unit and the data analysis processing unit are divided into two subsystem parts which are respectively used for pre-judging and accurately judging the state of the cutter.

The pre-judgment of the cutter state is realized as follows:

through the vibration sensor in the intelligent tool handle, a vibration signal in the machining process is detected and used as a signal input for system tool detection and pre-judgment.

The vibration sensor is integrated inside the intelligent tool handle, wireless transmission is adopted inside the tool handle, the device cannot compress the normal working space of the machine tool, the direction and the angle movement of the working motion part are not interfered, and the device is suitable for being applied to actual production. And signals acquired by the vibration sensor are transmitted to an external industrial computer in real time through wireless equipment to perform data processing analysis and judgment. The analysis, processing and judgment of the data are mainly completed by related software in an industrial computer, such as matlab software and the like during data processing and analysis.

In the actual machining process, the failure types of the cutter are mainly divided into two situations of excessive abrasion of the blade and cutter breakage. The tool wear can change the geometry of the tool, the cutting edge becomes dull, the cutting force can change during the cutting process, and further, the workpiece machining area can vibrate in different degrees. When the cutter is damaged, the deformation of the cutting part of the cutter is obvious, the cutting force can change rapidly in an instant, the vibration signal can also change rapidly, and the damage state of the cutter can be monitored by monitoring the transient change condition of the vibration signal in real time. The change process of the abrasion loss of the cutter is a gradual process, and in the actual processing process, the rear cutter face of the cutter is most easily abraded, so that the abrasion loss of the rear cutter face is usually selected as a monitoring object in the state monitoring of the cutter. The flank wear profile is substantially similar to the bathtub curve in shape, and as shown in fig. 25, the wear is divided into three stages, initial wear, normal wear, and rapid wear.

And the tool state pre-judgment module monitors the tool abrasion loss in real time through a machine learning SVM. The SVM is a machine learning algorithm established on the basis of a VC (virtual component modeling) dimension theory and a structure risk minimization principle of a statistical learning theory, and the dimension of vector features does not influence the algorithmThe complexity of the system not only saves time and cost, but also enables the establishment of the monitoring model to be simpler and more convenient. The classification of the SVM is an algorithm based on a binary classification principle, and is to map a tool wear characteristic training sample into a higher-dimensional space, establish an optimal classification hyperplane in the higher-dimensional space and divide different types of vectors in the space. The classification hyperplane can be used as a corresponding classifier in the data analysis processing unit, and the optimal classification hyperplane can be represented as omega^TΦ (x) + b ═ 0, where ω is an adjustable weight vector; b is a bias parameter, determining an offset value relative to the origin; Φ (x) is the feature mapping function. The monitoring mode is indirect measurement, machine learning training is carried out through tool wear historical experimental data, and a machine learning model meeting system requirements is obtained. In order to avoid the influence of other factors on the acquired vibration signals in the machining process of the machine tool, the acquired signals are subjected to feature extraction and used as the input of the SVM, the tool abrasion loss is used as the output, and a tool state pre-judgment model suitable for the system requirement is trained. In order to ensure that the accuracy of the finally trained model is high, a signal characteristic multi-method fusion extraction method is adopted in the characteristic extraction part to remove noise interference and extract effective information to the maximum extent.

In this embodiment, the description of the feature extraction of the signal vibration signal is performed by a method combining two signal processing methods, i.e., EMD empirical mode decomposition and principal component analysis. EMD is an important component of Hilbert-Huang transform of a new non-stationary signal which is emerging in recent years, and is suitable for analysis of linear and stationary signals and also suitable for analysis of non-linear and non-stationary signals. The essence of this method is to identify all vibration modes contained in the signal by a characteristic time scale, in which the characteristic time scale and the definition of IMF are empirical and approximate. Compared with other methods, the EMD method has intuitive, indirect, a posteriori, and adaptive characteristics, and the characteristic time scale used for decomposition is derived from the original signal, i.e. the signal is derived from the electric vibration signal which is collected by the driving motor such as the main shaft inside the machine tool and changes along with the time scale, and the specific decomposition process is as follows:

(1) finding all extreme points of the current vibration signal x (t);

(2) fitting the envelope curve e of the upper extreme point and the lower extreme point by using a 3-order spline curve_max(t) and e_min(t) obtaining the average value m (t) of the upper and lower envelope lines, and subtracting h (t) from x (t) -m (t);

(3) judging whether h (t) is IMF or not according to a preset criterion;

(4) if not, replacing x (t) with h (t), repeating the steps until h (t) meets the criterion, and then h (t) is the IMF needing to be extracted;

(5) every time one-order IMF is obtained, deducting it from the original signal, and repeating the above steps; until the last remaining part r of the signal_nIt is simply a monotonic or constant sequence.

Thus, the EMD decomposition decomposes the original current vibration signal x (t) into a series of IMFs and a linear superposition of the remaining components:

all information of tool abrasion in the machining process is covered by each order of inherent mode function obtained after the acquired current vibration signals are subjected to EMD decomposition, and in order to reduce the characteristic dimension of a machine learning algorithm, improve the machine learning efficiency and avoid the over-fitting problem of machine learning, a principal component analysis method is adopted to carry out principal component analysis on the inherent mode function obtained after EMD decomposition. Principal component analysis is a statistical method. A group of variables with possible correlation is converted into a group of linearly uncorrelated variables through orthogonal transformation, and the converted group of variables is called principal components. In the scheme, the inherent mode functions of each order after EMD decomposition are used as independent vectors of each group to be processed, and finally the principal component of the electric vibration signal after EMD decomposition is obtained. Through calculation of the contribution rates of different components, the first few orders of principal components with the information contribution rate of more than 85% are selected as input of vectors in machine learning.

In the processing process, the estimated value of cutter abrasion can be obtained by inputting a signal to the SVM according to real-time monitoring, the abrasion loss threshold value is automatically set according to a processing precision requirement system, generally, the cutter rear cutter face abrasion loss VB is 0.3mm as a default threshold value in most cases, when the cutter VB is larger than 0.3mm, the cutter can enter a sharp abrasion stage, the influence on the processing precision is large, particularly when the requirement on the processing precision is high, the parameter requirement input can be carried out on a manual interface, and at the moment, the cutter state prejudgment module automatically adjusts the VB abrasion threshold value according to the parameter requirement so as to guarantee the requirement of a machine tool cutter on the processing precision.

Along with the continuous improvement of machine learning theory and technical level in recent years, the identification accuracy of artificial intelligence on the aspect of monitoring the equipment state is higher and higher. However, in order to achieve accurate recognition of the tool state, the direct detection method is a poor choice. Therefore, after the cutter pre-judgment based on machine learning, the system verifies the pre-judgment result and accurately judges the state by applying a machine vision system, and simultaneously changes the state misjudgment in the pre-judgment module, thereby further improving the intelligent level of the numerical control equipment.

After the pre-judgment, the implementation manner of performing accurate judgment on the state of the tool is as follows:

the adopted direct measurement method of the cutter comprises the steps of cutter visual image acquisition and subsequent image comparison. And storing standard geometric dimension images of all the tools in the intelligent tool magazine of the numerical control machine tool in a system database unit. When the machine tool is in a cutter abnormal state, the data analysis module can call a standard cutter geometric image from a database according to the parameter information of the cutter in the current state and apply a professional image processing function module in the data processing unit to carry out multi-angle and multi-direction geometric dimension comparison calculation to obtain whether the cutter is abnormal or not and to specifically quantify the abnormal cutter state, and the system mainly refers to specific numerical values of cutter abrasion loss and whether the cutter is damaged or not. Along with the classification of the monitoring state of the cutter in the machining process, the module can be expanded.

In order to realize image acquisition, the design of the related motion function of the support motion part of the CCD camera and the performance requirement of the vision system for realizing image acquisition is required, and the specific design measures and schemes are as follows:

(1) the machine vision acquisition device comprises a magnetic seat part, the acquisition device is fixedly installed on a working tool post through the magnetic seat part, the origin of the fixed position on the tool post is set to be a workpiece coordinate system in a machine tool in a manner similar to the coordinate form of the machine tool, the workpiece coordinate system serving as the whole machine vision system in the machine tool coordinate system is called zero point coordinate, and the external machine vision acquisition device is connected with the machine tool coordinate system under the series connection of the zero point coordinate, so that the image acquisition device becomes a part of a numerical control processing system. The fixed position is the intersection point position of the circumferential line of the cylindrical tool post and the X-axis direction, and the consistency of the Y-axis coordinate point and the tool coordinate point is ensured. In the working process of a subsequent machine vision system, the requirement of the movement performance of the system can be met only by moving in the Z-axis direction and the X-axis direction, and the lens rotates up and down along the Y axis by acquiring the image in the axial direction of the bottom of the cutter through the rotating mechanism arranged on the connecting part of the CCD lens and the cutter bar. The machine vision system only acquires images at two azimuth angles in the circumferential direction and the axial direction, and meets the requirement of geometric dimension comparison in the image processing module. The machine vision system is integrally designed with a working guide rod capable of stretching and compressing, and when the machine vision system is in a working state, any spatial position of a working area can be reached through the guide rod on the X-direction axis and the Y-direction axis. A linear pull rope type displacement sensor is arranged in the tail end of the two-axis guide rod, coordinate values of the X axis and the Z axis during working are obtained through the linear pull rope type displacement sensor, the coordinate of the lens position in the machine tool is obtained through calculation by combining position data of the zero point coordinate in a machine tool workpiece coordinate system, and automatic position judgment and adjustment in the subsequent image acquisition process of the vision system are achieved. The machine vision system and the numerical control system are in communication connection, so that the lens position of the machine vision system can be monitored and controlled in real time by the numerical control system like a cutter. When the system is in a non-working state, each working guide rod is in a contraction state, the space volume occupied by the whole system is minimum, and the normal working space of the machine tool is not compressed.

The working guide rod adopts an electric telescopic rod device to realize the movement in the Z-axis and X-axis directions, and a pull rope type displacement sensor is arranged at the head of the electric telescopic rod device to detect and calculate the position coordinates of the camera lens. During installation, a measuring rod of the linear pull rope type displacement sensor is directly connected with a driver of the electric telescopic rod, the driver drives a sliding electric brush inside the sensor to generate displacement change, a direct current voltage signal which is linearly changed is output and provided for a system to calculate and store position coordinates of a camera lens into a numerical control system, and meanwhile, coordinate display is carried out on a display panel. Because the CCD camera needs to be connected with the system, in order to avoid the damage of the pole to the line in the telescopic process, a connecting line winding and unwinding device is designed, the principle is that a roller with a groove is designed, the line is wound on the roller through the groove, the roller motor is automatically driven to rotate forward and backward according to the telescopic length detected by the system, so that the winding and unwinding of the wiring harness are realized, and the problem that the data line faces excessively dragging or curling in the telescopic process is avoided.

(2) The premise of normal operation of the machine vision system is that the machine vision system has strong automatic focusing capability. In order to enable the machine vision system to have the characteristics of simple structure, stable system and strong robustness, the system selects a CCD camera to adopt a passive automatic focusing technology, and carries out automatic focusing according to imaging definition so as to meet the image acquisition requirement. The main function of the system is to further confirm the state and calculate and quantize the abnormal state of the abnormal cutter category monitored and judged in the initial stage, the abnormal state of the cutter in the initial stage mainly comes from the cutting edge area of the cutter, so the size of the focusing window of the vision system is automatically judged according to the real-time state parameter data of the numerical control system, for example, the working center position of the lens of the vision system is judged according to the coordinates of the cutter setting point, the parameter of the working cutter is checked and recorded according to the current cutter number transmitted by the numerical control system, the machine vision system automatically judges and divides the window of the focusing area according to the parameter characteristics of the current cutter, and the relevant parameters such as sampling frequency and the like are automatically decided and set in the image acquisition process, and the effectiveness and the accuracy of the acquired image are ensured by the means.

(3) The core of the machine vision system is the collection and processing of images, and the quality of the images is very critical to the influence of the whole system. The illumination light source is the most important factor for determining the image quality of the machine vision system, and the target characteristics and the background information in the image can be optimally separated by selecting a proper light source, so that the difficulty of image processing is greatly reduced, and the stability and the reliability of the system are improved. The machine vision system adopts the LED light source and selects the light source according to the engineering requirements of the geometric characteristics, the optical properties and the like of a machine tool cutter so as to meet the requirements of the machine vision system.

(4) After the machine tool is in an abnormal cutter state in the machining process, the main control system sends out a machine tool stop instruction, and the cutter rises to a safe position. Meanwhile, the machine tool simultaneously sends a work starting instruction to the machine vision system, the machine vision system is in a working state, after the CCD camera is quickly conveyed to the peripheral position of the cutter through the system internal position judging function module and the control system module according to the position coordinates of the cutter transmitted in the machine tool, a cutter image acquisition low-speed intermittent rotation instruction is sent to the machine tool working system, the main shaft rotates at a slow speed and intermittently, the CCD camera performs quick focusing and finishes image acquisition in a short time under the condition that the cutter is in a static state due to the rotation of the main shaft, the intermittent rotation of the main shaft is in high fit with the image acquisition frequency of the lens and the focusing time under the condition of dynamic image acquisition in beat, the phenomenon that the quality of an acquired image is influenced due to too fast rotating speed is avoided, the acquisition process time is increased too slowly, and the subsequent cutter changing and the. And after the image acquisition is received, transmitting the acquired picture information to the data information processing module, sending a main shaft stop instruction to the machine tool again, and completely withdrawing the working guide rods of the system to enable the system to be in a non-working state.

The whole machine vision system is developed by adopting an embedded system to realize the functions of image data acquisition, data transmission, component control, communication and the like, the embedded system technology comprises an integrated circuit technology, a system structure technology, a sensing and detecting technology, a real-time operating system and the like, and all the functions of the machine vision system can be realized under the technical support of the system.

The system is in communication connection with a plurality of module systems in the whole numerical control equipment and is connected with a data analysis processing module to further analyze image information and finish accurate diagnosis of the abnormal state of the cutter. And the machine tool control system is in communication connection with the machine tool control system to complete the matching action of the machine tool in the image acquisition process. And the data storage module is connected with the data storage module to realize the storage of data and the continuous filling and updating of database contents. And the display module is connected with the display module to realize process monitoring display in the image data acquisition process.

The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Although the present invention has been described with reference to the accompanying drawings, it is not intended to limit the scope of the present invention, and those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without inventive work are still within the scope of the present invention.

Claims

1. Digit control machine tool cutter state monitoring devices based on vibration signal and image acquisition, characterized by includes: the data acquisition unit and the data analysis processing unit; the data acquisition unit comprises a vibration state detection device and a machine vision acquisition device;

2. The apparatus for monitoring the state of a tool bit of a numerical control machine tool based on vibration signals and image acquisition according to claim 1, wherein a roller mounting box is further installed on one side of the magnetic base, the roller mounting box is installed in a roller mounting box fixing shell, a taper pin is arranged on the telescopic link connecting part, the Z-axis displacement sensor and the Z-axis electric telescopic link are fixedly installed through a Z-axis displacement sensor connecting plate, the X-axis displacement sensor and the X-axis electric telescopic link are fixedly installed through an X-axis displacement sensor connecting plate, and one end of the X-axis electric telescopic link is installed on the camera rotating bracket fixing device.

3. The apparatus for monitoring the state of a cutting tool of a numerical control machine tool according to claim 1, wherein the camera is a CCD camera, and the X-axis displacement sensor and the Z-axis displacement sensor are pull rope type displacement sensors.

4. The numerical control machine tool cutter state monitoring device based on vibration signals and image acquisition as claimed in claim 1, wherein a side wall threaded hole is formed in the side wall of the magnetic seat, a fixing groove is formed in the middle of the other side of the magnetic seat, and a magnetic seat knob is mounted at the top of the magnetic seat;

5. The apparatus for monitoring the state of a cutting tool of a numerical control machine tool according to claim 2, wherein the X-axis displacement sensor connecting plate and the Z-axis displacement sensor connecting plate have the same structure, and the plates are formed with connecting plate through holes and stepped holes, respectively.

6. The numerical control machine tool cutter state monitoring device based on vibration signals and image acquisition as claimed in claim 2, wherein a taper pin dismounting threaded hole is formed at the bottom of the taper pin.

7. The numerical control machine tool cutter state monitoring device based on vibration signals and image acquisition as claimed in claim 1, wherein one end of the X-axis electric telescopic rod is a telescopic rod connector, a fixing key groove is formed on the telescopic rod connector, and a connecting threaded hole is formed on a base of the other end of the X-axis electric telescopic rod.

8. The apparatus for monitoring the cutting tool state of a numerically controlled machine tool according to claim 1, wherein the upper support structure of the camera rotation mount fixing device is formed with a camera mount coupling screw hole for fixing with a camera, the middle support structure is formed with a coupling key groove through hole for coupling with an X-axis electric telescopic rod fixing key groove, and the bottom support structure is formed with a sensor connector coupling screw hole.

9. The numerical control machine tool bit state monitoring device based on vibration signal and image collection as claimed in claim 8, wherein the camera rotation bracket is provided with a camera fixing buckle and a camera rotation driving device, and the camera rotation driving device is provided with a connecting threaded hole for connecting with the camera bracket connecting threaded hole to realize the connection with the camera rotation bracket fixing device.

10. The numerical control machine tool cutter state monitoring device based on the vibration signal and the image acquisition as recited in claim 1, wherein the tool holder comprises a tool holder fixing part, a tool holder working part and a machining tool disc, a tool holder joint reinforcing ring is arranged between the tool holder fixing part and the tool holder working part, the tool holder joint reinforcing ring is fixed through a reinforcing ring fixing bolt and a reinforcing ring fixing nut, the machining tool disc is installed on the tool disc installing part, and the tool disc installing part is in threaded connection with the tool holder working part.