KR102523198B1 - processing system and method for cutter damage sensing and change time using external device - Google Patents

Abstract

The present invention relates to a system and method for detecting damage to a cutting tool using an external device and processing a replacement time, and more particularly, to a tool, which is the most important tool in using a machine tool using a CNC device of another company rather than a machine tool device applying its own CNC device. A system and method for detecting a cutting tool breakage and processing a replacement time using an external device that predicts tool life by defining a new standard through learning how to detect an error occurrence of the device. According to the present invention, it is possible to check functions at low cost by simultaneously providing a system for predicting the life of a tool and detecting an abnormal state of a tool in a simple module or interface manner instead of the existing tool detection method.

Description

Processing system and method for cutter damage sensing and change time using external device

The present invention relates to a system and method for detecting damage to a cutting tool using an external device and processing a replacement time, and more particularly, to a tool, which is the most important tool in using a machine tool using a CNC device of another company rather than a machine tool device applying its own CNC device. A system and method for detecting a cutting tool breakage and processing a replacement time using an external device that predicts tool life by defining a new standard through learning how to detect an error occurrence of the device.

In general, cutting processes such as milling, turning, drilling, and boring are performed on a dedicated machine tool or a machining center, which is an integrated equipment capable of various cutting processes. In particular, recently, the utilization of machining centers, which are advantageous for machining small-volume parts of various kinds, is increasing, and among machining centers, CNC machine tools perform precise cutting with micron-meter and sub-micron-meter dimensional accuracy by machining control of CNC (Computer Numerical Controller). this is possible

These CNC machine tools are NC (Numerical Control) machine tools with a built-in high-performance arithmetic unit. Data such as processing shape, processing conditions, and processing operations are automatically programmed by a computer and converted into NC data, and the converted NC data is It drives the machine tool in the pulse signaled state.

As described above, the CNC machine tool has an advantage in that it has high machining precision and can perform various types of cutting, but on the contrary, there is a problem of overload due to tool wear occurring during machining and unexpected tool damage due to this.

In particular, various failure diagnosis and life prediction programming are currently being diagnosed using various sensors in the field of smart factories at home and abroad, but there are still many limitations in terms of accurately predicting tool life accuracy from the outside using third-party CNC devices.

KR10-2020-0043619A

The present invention was devised to solve this problem, and analysis through synchronization work of processing programming in block units to provide a methodology for improving the above-mentioned disadvantages of the prior art and increasing accuracy, and accurately predicting tool life. To provide a cutting tool breakage detection and replacement timing processing system and method using an external device that can detect tool damage and problems in advance by generating a reference load waveform based on data to detect workpiece errors do.

In addition, in the present invention, even if the workpiece is changed, in the present invention, even if the workpiece is changed, the waveform is immediately formed by analyzing the workpiece programming, thereby reducing the resetting time for each one. An object of the present invention is to provide a system and method for detecting cutting tool breakage and processing replacement time using an external device capable of shortening the time.

In addition, the present invention connects and uses the machine tool device CNC equipment to obtain processing programming and load status, create a reference waveform using this, and detect tool life and damage status through continuous learning through this to optimize the tool tool life. It is possible to create a system configuration that detects and informs users of information or stops equipment, and cutting tool breakage detection using an external device that can predict tool life and detect breakage in a relatively inexpensive and accessible way to the general public. And to provide a replacement timing processing system and method.

According to one aspect of the cutting tool damage detection and replacement timing processing system using an external device according to the present invention for achieving the above object, CNC equipment for generating CNC data; a personal computer that divides and matches the waveform and processing programming generated from the CNC data into blocks and then generates a reference waveform profile; And storing the reference waveform profile generated by the personal computer and comparing the input waveform with the reference waveform profile when processing the same workpiece in the CNC equipment to check the wear and tear condition of the tool according to the load condition and use time of the tool and a single board computer that predicts the life of the tool based on number of times of use.

In addition, the single board computer receives CNC data including spindle feed information, command value, and spindle load data from the CNC equipment to generate a load state graph or transmits CNC data to the personal computer to store a generated reference waveform profile. Based on the reference waveform profile and the load state graph, the cutting standards that have actually been machined are divided into blocks to match the graphics, and after checking the maximum value, a data table is created and saved such as CNC data including the machining programming name and tool number. management, and when the value of the newly input load is different or greater than or less than the reference value based on the reference waveform profile, an emergency stop signal may be output to the CNC equipment or an abnormal state alarm message may be transmitted.

In addition, the single board computer accumulates counter information and machining time information when selecting a counter in the CNC equipment to determine tool life replacement timing through a tool life derivation algorithm, or processing time information when selecting a machining time in the CNC equipment. By accumulating and counter information, the tool life replacement timing can be determined through the tool life derivation algorithm.

On the other hand, according to one aspect of the cutting tool damage detection and replacement time processing method using an external device according to the present invention for achieving the above object, the step of CNC equipment generating CNC data; dividing, by a personal computer, the waveform generated from the CNC data and processing programming into blocks, matching them, and then generating a reference waveform profile; And the single board computer stores the reference waveform profile generated by the personal computer and compares the input waveform with the reference waveform profile when processing the same workpiece in the CNC equipment to check the wear and tear of the tool according to the load condition It may include estimating the life of the tool based on the time and number of uses of the tool.

In addition, in the step of checking the wear and tear of the tool according to the state of the load and predicting the life of the tool based on the use time and number of use of the tool, the single board computer receives spindle feed information and commands from the CNC equipment receiving CNC data including value and spindle load data to generate a load state graph or transmitting CNC data to the personal computer and storing the created reference waveform profile; Based on the reference waveform profile and the load state graph, the single board computer divides the actual machined cutting standards into blocks, matches the graphic, checks the maximum value, and then checks the maximum value. Generating and storing and managing; and outputting an emergency stop signal or transmitting an abnormal state alarm message to the CNC equipment when the value of the newly input load is different or is greater than or less than the reference value based on the reference waveform profile. can do.

In addition, in the step of checking the wear and tear of the tool according to the state of the load and predicting the life of the tool based on the time and number of times of use of the tool, the single board computer provides counter information when selecting a counter in the CNC equipment The tool life replacement time is determined through the tool life derivation algorithm by accumulating the tool life time information and the tool life replacement time through the tool life derivation algorithm by accumulating the machining time information and counter information when the machining time is selected in the CNC equipment It may further include the step of determining.

According to the present invention, it is possible to check functions at low cost by simultaneously providing a system for predicting the life of a tool and detecting an abnormal state of a tool in a simple module or interface manner instead of the existing tool detection method.

In addition, conventionally, the CNC selects and uses one of the counter of the tool or the usage time of the tool, but in the present invention, if the CNC device selects one, the other is selected by the present device and predicts the lifespan of the two at the same time. Also, there is an effect of processing the method of diagnosing the abnormal state of the tool through programming and synchronizing the load spindle state in block units.

In addition, there is an advantage in that it is possible to measure a load equal to or better than the conventional sensor attachment method in terms of cost and accuracy, and there is no need for new measurement management even if the material or processing itself is changed.

1 is a diagram showing a method for detecting a general machine tool cutting tool breakage.
Figure 2 is a view showing the overall configuration of the machine tool cutting tool breakage detection function analysis processing system device and replacement time and method according to an embodiment of the present invention.
3 is a diagram showing a tool life check structure and method according to an embodiment of the present invention.
4 is a diagram showing an example of a tool breakage detection or prediction output signal connection diagram according to an embodiment of the present invention.
5 is a diagram illustrating processes of cutting, waveform matching, and graph generation according to an embodiment of the present invention.
6 is a diagram illustrating waveform processing when a tool tool is normal and abnormal according to an embodiment of the present invention.
7 is a diagram showing a data processing configuration when there are actually several machines according to an embodiment of the present invention.
8 is a flowchart illustrating a machine tool cutting tool breakage detection function analysis processing system device and method according to an embodiment of the present invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Prior to this, the terms or words used in this specification and claims should not be construed as being limited to the usual or dictionary meaning, and the inventor appropriately uses the concept of the term in order to explain his/her invention in the best way. It should be interpreted as meaning and concept consistent with the technical idea of the present invention based on the principle that it can be defined. Therefore, the embodiments described in this specification and the configurations shown in the drawings are only the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention, so various alternatives can be made at the time of this application. It should be understood that there may be equivalents and variations.

1 is a diagram showing a general machine tool cutting tool breakage detection method, and FIG. 2 is a diagram showing a machine tool cutting tool breakage detection function analysis processing system apparatus and replacement time and overall configuration of the method according to an embodiment of the present invention. .

As shown in the figure, in order to detect or recognize the existing tool tool breakage, the big data of No. ⑥ was processed through the route ①, but in the present invention, No. ② (in the case of an embedded PC-CNC) or No. 5 (in the case of an embedded CNC) It can be treated in different ways. In this method, the processing cutting programming is divided into division methods, and a reference waveform is created by matching the waveform, and the state of the tool can be quickly judged by comparing the processing state to be newly processed by making a profile and quickly determining the state of the tool. By this judgment, it is possible to limit defects in advance by immediately applying a limit to the feed axis feed like the direct feed axis over trouble limit, and the accuracy of the replacement time of the machining tool is also determined by combining the counter and time. can increase

In the past, a method of detecting and judging data through an A/D board by installing a sensor in a device or using an I/O processing method through a PLC was mainly used, but the present invention uses the data generated by the CNC equipment 100 After dividing and matching the waveform and processing programming in block units, the basic waveform is created in the personal computer (300) to create a more accurate standard processing profile, and then this waveform or data is converted into a single board computer (200) After storing it in the future, when the same product is processed, it becomes a reference point to grasp the state of the load to check the state of wear and damage of the tool, and through this, it is possible to detect defects in the processed product.

In addition, the present invention selects and uses only one of the use time of the tool or the number of use of the tool in the CNC while separately selecting the case of the TC model and the case of the MC model, but by using both, a more accurate tool Life expectancy can be predicted.

3 is a diagram showing a tool life check structure and method according to an embodiment of the present invention.

As shown, in the existing tool alarm processing method, only one method of a counter or a tool use time is used. Therefore, in the present invention, the tool replacement cycle can be efficiently applied by applying a method of processing using both the tool use time and the number of counters, and both can be processed by processing as follows.

을 통해 받은 타임을 계산하여 M1에서 받은 카운터와 싱글 보드 컴퓨터(B)에서 계산한 가공시간 타임을 누적 계산을 하여 합쳐서 최적의 알고리즘을 통해 공구(툴) 수명 교체시기를 결정하여 알려주도록 한다. 그리고 퍼스널 컴퓨터(C)를 통한 학습 알고리즘 등을 통해 최적의 데이터를 얻도록 할 수 있다.First, if the counter is set in the CNC device in M1, the single board computer (B) in FIG.

By calculating the time received through the accumulated calculation of the counter received from M1 and the machining time calculated from the single board computer (B), the tool (tool) life replacement time is determined and notified through the optimal algorithm. In addition, it is possible to obtain optimal data through a learning algorithm or the like through a personal computer (C).

And, in the opposite case, if the time is selected in M1, the single board computer (B) selects a counter and accumulates the two information to determine and notify the tool (tool) life replacement period through an optimal algorithm. there is.

In addition, when the life of the tool is over or it is damaged, as shown in FIG. 2, the ③ E-STOP function is operated through the I/O contact of the single board computer (B) or an alarm message is output so that the CNC and user of M1 can make it possible to recognize.

4 is a diagram showing an example of a tool breakage detection or prediction output signal connection diagram according to an embodiment of the present invention.

As shown, in reality, the equipment connection diagram can be connected to E-STOP by connecting the tool detection (T+ or T-) equivalently to the existing limit switch for each axis and configuring it as shown in the connection diagram ③, ③ Number 1 shows an example of the connection with E-STOP in case of wanting to limit the feed axis of the CNC device after detecting tool breakage.

In addition, as a system mounted on the H/W system module of the present invention, it is possible to embed an I/O contact and configure it in the form of an app or application with an external device such as a single board computer (B) module and a mobile phone to input data. can do.

를 통해 CNC DATA인 스핀들 피드 정보(***%), 지령 값(S***), 스핀들 부하 데이터를 전달받아 싱글 보드 컴퓨터(B) 모듈에서 부하 상태 그래프를 만들거나 또는 데이터를 퍼스널 컴퓨터(C) 모듈에 전송하여 만들 수 있다. 퍼스널 컴퓨터(C) 모듈에서 만든 프로 파일은 다시 싱글 보드 컴퓨터(B) 모듈에 저장하여 기준 파형으로 활용할 수 있다.Also, from the CNC of the M1 device in FIG.

Sends spindle feed information (***%), command value (S***), and spindle load data, which are CNC data, through C) It can be created by sending it to the module. The profile created in the personal computer (C) module can be stored in the single board computer (B) module again and used as a reference waveform.

를 통해 CNC DATA인 프로그래밍명, 툴 번호 등을 체크하여 확인할 수 있다. 상기 싱글 보드 컴퓨터(B) 모듈에 전송된 가공 프로파일과 생성된 부하 상태 그래프를 가지고 실제로 가공이 된 절삭 기준으로 블록 단위로 나누어 그래픽을 매칭하고 최대값을 확인한 후 데이터와 같이 데이터 테이블을 만들어 저장 관리할 수 있다.Also, from the CNC of the M1 device in FIG.

You can check and confirm the programming name, tool number, etc., which are CNC data, through . With the processing profile transmitted to the single board computer (B) module and the generated load state graph, the cutting standard that has actually been processed is divided into blocks, the graphics are matched, the maximum value is checked, and a data table is created and stored as data. can do.

In addition, stored data can be managed by matching with each processing programming number, and repeated waveforms can be continuously managed and updated in the personal computer (C) module, and when modifications and changes are applied, they are returned to the single board computer (B) module. can be updated.

등 다양한 에러 메시지를 전달할 수 있다.In addition, when the value of the load newly input with the reference waveform or reference value stored in the single board computer (B) module is different or is greater than or less than the reference value, an alarm is generated, as described above.

Various error messages can be delivered.

In addition, by adding sensor data such as vibration, current, energy, etc., the vibration data input through A/D conversion and processing programming are divided and matched in block units to profile the processing state, and compare the spindle load graph. The state of the cutting tool can be judged and determined by comparing and checking the state of the cutting process with the block machining programming. The cutting process, waveform matching, and graph generation process are as illustrated in FIG. 5 .

5 is a diagram illustrating processes of cutting, waveform matching, and graph generation according to an embodiment of the present invention.

As shown, the waveforms for cutting by GCODE from GCODE 1 to GCODE n appear, and the waveforms can be displayed in the order of block unit synchronization work vibration waveform 1, synchronization vibration waveform 2, and block unit synchronization vibration waveform 3. there is. Matching can be performed through waveform extraction for block unit synchronization and matching between cutting programming and block synchronization.

That is, as illustrated in FIG. 5, the waveforms are divided in blocks, and cutting codes are added to the divided waveforms in blocks to make up to n codes from GCODE 1 to GCODE n, and comparison can be continued. Here, dividing the waveform into block units means that when a cutting operation is performed in the CNC equipment and the cutting waveform is continuously input, there may be a cutting section and a non-cutting section. In addition, cutting may include t1 machining, t2 machining, and t3 machining, and since each tool has a number, the machining tool number and the corresponding cutting code can be matched on a block basis. That is, it is possible to match cutting codes in block units so that they can be matched with machining programs up to n times.

6 is a diagram illustrating waveform processing when a tool tool is normal and abnormal according to an embodiment of the present invention.

As shown, waveform extraction in the case of normal (clustering based P normal detection) and waveform extraction in the case of abnormality are shown. In the case of normal waveform extraction, the vibration signal generated during the milling operation can be detected through the sensor, and the waveform is extracted according to the detected signal. Meanwhile, the waveform extraction in the abnormal case represents an abnormal case in which the waveform is not extracted because the vibration signal generated during the milling operation is not detected through the sensor. That is, if the machining tool of the CNC equipment for the cutting operation is normal, the waveform continues to appear, so one can be selected and the reference waveform and the input waveform can be compared. However, in the case of abnormality, the waveform may not appear as illustrated.

In this way, there is an advantage of checking functions at low cost by simultaneously providing a system for predicting the life of a tool and detecting an abnormal state of a tool in a simple module or interface manner instead of the conventional tool detection method. In addition, conventionally, the CNC selects and uses one of the counter of the tool or the usage time of the tool, but in the present invention, if the CNC device selects one, the other is selected by this device and predicts the life first with two at the same time. It can also handle the method of diagnosing the abnormal state of the tool through programming and synchronizing the state of the load spindle in units of blocks. Therefore, it is possible to measure the load equivalent or better in cost and accuracy than the existing sensor attachment method, and there is an advantage that there is no need for new measurement management even if the material or processing itself is changed.

7 is a diagram showing a data processing configuration when there are actually several machines according to an embodiment of the present invention.

As shown, if there are several mechanical devices such as mechanical device A, mechanical device B, and mechanical device C, in Customized Model A-Type, monitoring data for each device and various sensor information data are collected through Customized Model A'-Type Afterwards, the Customized Model A'-Type model can be repeatedly and continuously updated through machine learning that receives actual processing data and simulator data. Here, data analysis can be performed through synchronization work in block units, waveforms can be generated for each equipment, and comparison can be made using the generated waveforms.

8 is a flowchart illustrating a machine tool cutting tool breakage detection function analysis processing system device and method according to an embodiment of the present invention.

As shown, communication with the CNC equipment may be initiated and CNC data may be received from the CNC equipment. The CNC data may include a tool use count value, tool use time value, program name, tool number, F value, S value, spindle load value, execution programming information, and the like. At this time, a key value may be input from an external device. In other words, if the operator claims that this tool will be defective after using it 10 times based on her own experience, the operator can arbitrarily input data even before machine learning. When CNC data is transmitted from the CNC equipment, a waveform can be created from the spindle load data. For example, a waveform can be created in a machining program. In the present invention, by generating a waveform based on the state of the load, such as the F value, S value, and spindle load value of the CNC equipment, the change value of the load can be continuously measured, and a machining program can be used here. In addition, the vibration sensor data of the CNC equipment can be input to the personal computer (C) module without passing through the single board computer (B) module, and at this time, the vibration sensor data waveform of the CNC equipment is the same unless the value is artificially changed. can be entered.

Subsequently, a tool replacement comparison may be performed by collecting a tool usage count value and a tool usage time value. That is, as shown in FIG. 2, when data is sent from the single board computer (B) module to the personal computer (C) module, the personal computer (C) module creates a profile and matches it with the processing program, so that only the profile is used by the single board computer (B) can be stored in a module. After that, it is possible to check whether the second and third input data are sequentially compared to exceed the limit.

In addition, in CNC equipment, tool use time can be measured or the number of tool use counters can be performed. In the present invention, both the tool usage time and the tool usage count counter can be mixed. That is, if a tool failure occurs at a certain point in time, when the time is accumulated and compared with the profile, the time at which the counter should not exceed this point can be set through learning.

In addition, in the case of counting only the number of times of tool use, the value may not be constant depending on the skill of the operator, but if the tool use time is mixed, the probability may increase. close accuracy can be achieved. That is, if the counter count is checked at a certain point in time when a defect occurs, the checked counter and time are stored, and later when a similar number is detected when the counter is detected, if the time value is also within a certain range, it can be determined that the defect is highly likely. can

Then, machine cut programming block data comparison can be made. At this time, machining and cutting programming block data can be compared based on the sensor data information waveform.

Then, profile graphs and data comparisons can be performed, and profiles and data accumulation can be performed. In this case, when an update is required in the profile and data accumulation step, a step of comparing tool replacement by collecting a tool usage count value and a tool usage time value may be performed.

Then, based on the accumulated profile and data, a tool replacement cycle can be determined. At this time, when the replacement period is undetermined, a step of comparing the tool replacement by collecting the tool use count value and the tool use time value may be performed.

Subsequently, when the tool replacement cycle is determined, an alarm level may be determined. At this time, the alarm level is determined by the emergency stop (E-STOP) signal output for emergency stop of the equipment as shown in FIG. Equipment may be stopped in an emergency. In addition, since there may be a malfunction of the equipment, it is possible to generate only an alarm message while moving the axis in preparation for malfunction. That is, when an alarm is generated due to an abnormal state of the CNC equipment, the equipment may be immediately stopped to stop cutting or only an alarm message may be generated without stopping the feed axis.

In this way, the present invention provides a method for increasing efficiency in predicting the life of a machining tool at a low cost, and a method for easily managing a tool even when a workpiece is changed through a new machining block unit cutting synchronization in addition to the existing measurement method, thereby enabling tool management through this. prediction accuracy can be improved.

In addition, the present invention can provide a method for predicting an optimal exchange state using both a counter and a time method related to tool life prediction at the same time and a configuration system thereof.

In addition, in the present invention, the graph created in the task of synchronizing the machining programming with the CNC load information, spindle command speed, magnification %, etc. in block units is profiled, stored in the single board computer (B), and then tool abnormal state through comparative search. A system and diagnostic method capable of immediate detection can be provided.

In addition, in the present invention, an algorithm that obtains CNC data through communication with a module having I/O contacts and communication functions in a single board computer (B) and compares the existing machining counter and machining time to determine the optimal replacement cycle. And it is possible to provide a method of stopping the equipment by detecting the tool breakage based on the created profile.

In addition, in the case of a general embedded machine tool, a single board can be mounted and processed externally, and in the case of a PC-type structure, the system can be configured by embedding it as an app inside.

As described above, although the present invention has been described by the limited embodiments and drawings, the present invention is not limited thereto, and the technical spirit of the present invention and the following by those of ordinary skill in the art to which the present invention belongs Of course, various modifications and variations are possible within the scope of equivalents of the claims to be described.

100: CNC equipment
200: single board computer
300: personal computer

Claims (6)

CNC equipment generating CNC data;
a personal computer that divides and matches the waveform and processing programming generated from the CNC data into blocks and then generates a reference waveform profile; and
Stores the reference waveform profile generated by the personal computer and compares the input waveform with the reference waveform profile when machining the same workpiece in the CNC equipment to check the wear and tear of the tool according to the load condition, a single board computer that predicts tool life based on the number of uses;

The single board computer,
Receiving CNC data including spindle feed information, command value, and spindle load data from the CNC equipment to generate a load state graph;
Receiving vibration data, current data, and energy data from the vibration sensor, current sensor, and energy sensor provided in the CNC equipment through the AD converter to generate a processing state graph,
storing the reference waveform profile generated by transmitting CNC data to the personal computer;
Based on the reference waveform profile, the load state graph, and the machining state graph, data such as CNC data including the machining programming name and tool number after dividing the block by block and matching the graphic and checking the maximum value are actually processed cutting standards. Create and store tables,
When the value of the load newly input based on the reference waveform profile and the load state graph is different or is greater than or less than the reference value, vibration data, current data, and energy data newly input based on the processing state graph are within the reference range , outputs an emergency stop (E-STOP) signal to the CNC equipment or delivers an abnormal state alarm message,
Accumulating tool processing time information and tool usage count information in the CNC equipment determines the tool life replacement time through a tool life derivation algorithm,

The personal computer,
a tool detection switch connected in series with at least one axis limit switch;
When tool breakage is detected, an emergency stop (E-STOP) switch is shorted by the tool detection switch to limit the movement of the feed axis of the CNC equipment,

The personal computer,
When the CNC equipment is at least two, continuously updated based on data derived through a machine learning algorithm that collects monitoring data and sensor information data of the CNC equipment and receives actual processing data and simulator data of the CNC equipment customized prime model; and
A cutting tool breakage detection and replacement timing processing system using an external device comprising a; customized model receiving monitoring data from the customized prime model. delete delete delete delete delete

Images