KR102661532B1 - Machine tool real-time monitoring system and method therefor - Google Patents

Abstract

The present invention includes a camera installed on one side of a machine tool to photograph the operating state of the machine tool; a control device installed on the other side of the machine tool to control and process signals input from the outside, receive an operating image of the machine tool from the camera in real time, and control the image to be output to the outside; At least one temperature sensor installed on one side of the control device to measure the temperature of the operating machine tool; At least one vibration sensor is installed on the other side of the control device to measure a vibration state of the operating machine tool; an AD converter that inputs data from the temperature sensor and the vibration sensor to the control device so that the control device processes and outputs the data; an image processing device that processes the image received from the control device to be output; an image processing device that inputs and outputs the data to an image processed by the image processing device; a streaming device that streams and outputs the video data input from the video processing device; At least one monitoring device that outputs the image received by the streaming device to check the operating state of the machine tool and determines whether to replace the machine tool parts; provides a real-time monitoring system for a machine tool including a.

Description

Real-time monitoring system and method for machine tools {MACHINE TOOL REAL-TIME MONITORING SYSTEM AND METHOD THEREFOR}

The present invention relates to a real-time monitoring system and method for machine tools, and more specifically, to a machine tool monitoring system that monitors machine tools in real time to check the operating status of the machine tool and determine whether to replace machine tool parts. It relates to a real-time monitoring system and method.

Machine tools are a general term for mechanical devices that process workpieces using tools.

When processing is performed by operating such a machine tool, a manager resides around the machine tool to visually monitor the current processing status or control the machine tool.

The first prior patent document designed to solve the above problems is a remote monitoring and control system for machine tools in Patent Publication No. 10-2006-0043943 (published on May 16, 2006).

The remote monitoring and control system for machine tools in the above-described first prior patent document includes a device that receives monitoring screen data from a controller, a device that displays a monitoring screen on a screen based on the monitoring screen data, and the controller. It includes a device that controls the machine tools by transmitting keyboard signals to the machine.

In addition, the remote monitoring and control system for machine tools in the first prior patent document has a controller information window that displays information about the connected controller on the monitoring screen, and a screen transmission window that displays an operation screen of the connected machine tool. Includes.

And as a second prior patent document related to the present invention described later, there is a machine tool operation monitoring system of Registered Patent Publication No. 10-2274862 (registered on July 2, 2021).

The machine tool operation monitoring system of the above-mentioned second prior patent document is a system that detects abnormal operation of a machine tool that performs cutting processing on materials, and is a system that detects the torque or speed of the drive motor in each of the plurality of machine tools. If it exceeds the range due to normal operation, or the movement position of the component parts of the machine tool and the material operated by the drive motor in the reciprocating or rotating movement is within the range of the area due to the prescribed normal operation. If it exceeds this value, the reflective display board provided in each machine tool is moved to a position where it can reflect the lighting light in the factory, and the reflected light is projected onto the camera that is photographing each machine tool, and the image related to the projection is projected. By monitoring, machine tools that are malfunctioning are identified.

In addition, the operation monitoring system of the machine tool in the second prior patent document sets the input voltage or input current to the drive motor based on the torque or the speed or the normal operating range at the operating position, A number is assigned to each machine tool, and the machine tool identified by detection of an operating abnormality is further identified by video display of the number.

However, the above-described first and second prior patent documents have a problem in that they are not suitable for application in monitoring the operating status of a machine tool and determining, for example, whether to replace worn-out machine tool parts.

1. Patent Publication No. 10-2006-0043943 2. Patent Registration Patent Publication No. 10-2274862

The present invention was created to solve the above problems, and includes a real-time monitoring system for machine tools that monitors machine tools in real time to check the operating status of machine tools and determine whether to replace machine tool parts. The purpose is to provide a method.

The real-time monitoring system for machine tools of the present invention to achieve the above purpose is,

A camera installed on one side of the machine tool to photograph the operating state of the machine tool;

a control device installed on the other side of the machine tool to control and process signals input from the outside, receive an operating image of the machine tool from the camera in real time, and control the image to be output to the outside;

At least one temperature sensor installed on one side of the control device to measure the temperature of the operating machine tool;

At least one vibration sensor is installed on the other side of the control device to measure a vibration state of the operating machine tool;

an AD converter that inputs data from the temperature sensor and the vibration sensor to the control device so that the control device processes and outputs the data;

an image processing device that processes the image received from the control device to be output;

an image processing device that inputs and outputs the data to an image processed by the image processing device;

a streaming device that streams and outputs the video data input from the video processing device;

It is characterized in that it includes; at least one monitoring device that outputs the image received by the streaming device to check the operating state of the machine tool and determines whether to replace the machine tool part.

In the present invention, a first proximity sensor is connected to the control device to check the processing amount of the workpiece of the machine tool, and a second proximity sensor is connected to the control device to measure the RPM of the machine tool.

In the present invention, the temperature sensor includes a thermistor temperature sensor, and the vibration sensor includes a piezo vibration sensor.

The real-time monitoring method of the machine tool of the present invention to achieve the above purpose is,

(a) photographing the operating state of the machine tool with a camera installed on the machine tool;

(b) controlling the control device installed on the machine tool to receive and output an operating image of the machine tool from the camera in real time;

(c) the control device receives the temperature and vibration status of the machine tool in real time from a temperature sensor and a vibration sensor connected to the control device and outputs them together with the image;

(d) image processing the image received from the control device;

(e) calculating a resistance value according to the output temperature of the temperature sensor, calculating the operating temperature of the machine tool using a function of the resistance value and the temperature value, and inputting the result to an image processing device;

(f) the image processing device inputting input data including the input temperature into the image;

(g) inserting a warning window into a warning window when the temperature value (T) input to the image processing device is higher than a predetermined temperature;

(h) determining whether the voltage value (V) of the vibration sensor input to the image processing device is 5V or more, and inserting a warning window if the voltage value (V) is 5V or more;

(i) streaming the image-processed video, the temperature sensor, and the vibration sensor data and outputting the data to at least one remote monitoring device.

In the present invention, (j) in step (b), the control device receives and processes data in real time from the first proximity sensor installed on the machine tool in order to determine the processing quantity of the workpiece processed by the machine tool. steps and; (k) determining whether an interrupt has occurred in the data input by the first proximity sensor, and if the interrupt has occurred, outputting a count, inputting the data to the image processing device, and outputting the data to the monitoring device; do.

In the present invention, (l) in step (b), the control device receives and processes data in real time from a second proximity sensor installed on the machine tool in order to measure the rotation speed (RPM) of the machine tool. Steps and; (m) determining whether an interrupt has occurred in the data input by the second proximity sensor, and if the interrupt has occurred, recording the time between the rising time and the falling time of the second proximity sensor; (n) determining whether a time record of the rising time and the falling time exists, calculating and outputting the RPM of the machine tool, inputting it to the image processing device, and outputting the RPM to the monitoring device. .

In the present invention, data from the temperature sensor and the vibration sensor are input to the control device through an AD converter.

According to an embodiment of the present invention, by photographing a working machine tool and applying a temperature sensor and a vibration sensor to it to output data and images measuring the temperature and vibration level of the operating machine tool, the machine tool can be operated from a remote location. The operating status can be judged visually, and if the machine tool rises to a certain temperature or vibrates, it can be confirmed whether a specific part (or tool) of the machine tool should be replaced.

In addition, the productivity of the machine tool can be determined through data acquired through the first proximity sensor, and the rotational speed (RPM) or rotation speed of the machine tool can be determined through data acquired through the second proximity sensor to determine the machine tool's productivity. You can check whether it is operating normally, so you can check the degree of aging of a specific part (or tool) or whether it should be replaced.

Therefore, there is no need to replace all expensive machine tools, replacement times can also be known, and the present invention can be implemented using low-cost devices.

1 is a block diagram showing the overall configuration of a real-time monitoring system for a machine tool according to the present invention.
Figure 2 is a flow chart sequentially showing the real-time monitoring method of a machine tool according to the present invention.
Figure 3 is a monitor screen of a monitoring device on which data obtained from a temperature sensor and a vibration sensor according to an embodiment of the present invention is output.
Figure 4 is a monitor screen of a monitoring device with a counter function and time output according to an embodiment of the present invention.
Figure 5 is a monitor screen of a monitoring device on which measured RPM values are output according to an embodiment of the present invention.
Figure 6 is an example photo showing multi-monitoring implemented according to an embodiment of the present invention.

Hereinafter, preferred embodiments according to the present invention will be described in detail with reference to the attached drawings.

Figure 1 shows a block diagram showing the overall configuration of a real-time monitoring system for a machine tool according to the present invention.

Referring to FIG. 1, the real-time monitoring system for a machine tool according to the present invention includes a camera installed on one side of a machine tool 1, such as an aging lathe, to capture the operating state of the machine tool 1. (11) is installed on the other side of the machine tool (1) to control and process signals input from the outside, receive images of the operation of the machine tool (1) in real time from the camera (11), and output the images to the outside. It is configured to include a control device 13 that controls it as much as possible.

The control device 13 is a device that functions like a kind of computer (PC), and can be used with Raspberry Pi, an ultra-small and low-cost mini personal computer.

Therefore, it is desirable to use a small camera module that can be connected to a small computer such as Raspberry Pi as the camera 11.

And the real-time monitoring system of the machine tool according to the present invention includes a temperature sensor 33 that measures the temperature of the machine tool 1, at least one of which is installed on one side of the control device 13 and operates, and the control device ( At least one vibration sensor 32 is installed on the other side of 13) to measure the vibration state of the operating machine tool 1, and the analog data of the temperature sensor 33 and the vibration sensor 32 are processed into digital signals. It is configured to include an AD converter (Analogue-Digital Converter) 31 that converts analog data into digital data by inputting it to the control device 13, which is a device, so that it is processed and output.

The temperature sensor 33 includes a thermistor temperature sensor, which is a resistor whose resistance changes sensitively according to changes in temperature. That is, the thermistor temperature sensor is a sensor that measures temperature using resistance change according to the temperature of the ceramic material.

The vibration sensor 32 is a piezo-type vibration sensor, and detects the degree of vibration by converting the sensed vibration into a voltage (or electric) signal.

These temperature sensors 33 and vibration sensors 32 are output as analog signals, and therefore, in order to receive and process the output analog signals in the control device 13, which is a digital device, an AD converter converts the analog signals into digital signals. (31) is provided.

The AD converter 31 and the control device 13 only need to be provided with two communication lines (SDA, SCL lines), and can communicate with multiple masters or slaves. It is a synchronous communication method using a clock signal, so it can be time-free. 12C (Inter-Integrated Circuit) communication is applied.

That is, the AD converter 31 is installed so that the sensing information or data of the temperature sensor 33 and the vibration sensor 32 is input as an analog signal to the control device 13, which is a digital device. ) reads voltage values, etc. from the temperature sensor 33 and the vibration sensor 32 to the control device 13.

And the AD converter 31 transmits voltage values, etc. to the control device 13 through 12C communication.

In addition, the real-time monitoring system of a machine tool according to the present invention includes an image processing device 15 that processes the image received from the control device 13 to be output from monitoring devices 23a to 23n, which will be described later, and the sensors An image processing device 17 that inputs the data of (32, 33) into the image processed by the image processing device 15 and outputs it from monitoring devices 23a to 23n, which will be described later, and from this image processing device 17 It is configured to include a streaming device 19 that streams and outputs images with input data.

In addition, the real-time monitoring system of the machine tool according to the present invention outputs the video received from the streaming device 19 to check the operating status of the machine tool 1 and determines whether to replace parts of the machine tool 1. At least one monitoring device (23a to 23n) and a network device (21) that transmits video from the streaming device 19 to the remote monitoring devices (23a to 23n) through network communication are provided.

The monitoring devices 23a to 23n include a computer (PC) or server equipped with a monitor.

And, the network equipment 21 is sufficient as ordinary communication equipment capable of Internet communication.

In addition, the control device 13 is connected and installed with a first proximity sensor 41 for checking the amount of workpiece processing of the machine tool 1, and for measuring the RPM (rotation speed) of the machine tool 1. The second proximity sensor 41 is connected and installed.

The real-time monitoring method of a machine tool according to the present invention using the real-time monitoring system of a machine tool according to the present invention having the above-mentioned configuration will be described as follows.

Figure 2 shows a flow chart sequentially showing the real-time monitoring method of a machine tool according to the present invention.

Referring to FIGS. 1 and 2, the real-time monitoring method of a machine tool according to the present invention first uses a camera (small camera module) 11 installed on one side of a machine tool 1, such as an aging lathe, to monitor the machine tool ( 1) Photograph the operating state (step 110).

Next, the control device 13 installed on the machine tool 1 receives the operating image of the machine tool 1 from the camera 11 in real time and controls the video to be output to the outside (step 120).

In addition, the control device 13 detects the temperature and vibration status of the machine tool 1 in real time from the temperature sensor 33 and the vibration sensor 32 connected to the control device 13 through the AD converter 31. Receive input and output together. (Steps 130 and 140)

Next, the image received from the control device 13 is image processed by the image processing device 15 (step 150).

In addition, the resistance value according to the temperature value received from the output temperature sensor 33 is calculated, and the temperature during operation of the machine tool 1 is calculated using the function of the resistance value and temperature value, and the image processing device ( Enter in 17). (Steps 160, 170, 180)

The image processing device 17 inputs input data, such as the temperature during operation of the machine tool 1 and the voltage value of the vibration sensor 32, into the image output from the image processing device 15. Print out. (Step 190)

Subsequently, if the temperature value T input to the image processing device 17 is higher than a predetermined temperature (50°C), it is inserted (or output) into the monitor warning window of the monitoring devices 23a to 23n, which will be described later. (Step 210,220)

And if the temperature value (T) is below a predetermined temperature (50°C), it is determined whether the voltage value (V) of the vibration sensor 32 input to the image processing device 17 is 5V or more, and the voltage value (V) is determined. If it is more than 5V, it is inserted (or output) in the warning window (steps 230 and 240).

In this way, the thermistor temperature sensor is applied to measure the charge drop value that occurs within the thermistor, and the charge drop value is used to calculate the resistance value of the thermistor, which is then calculated as a temperature-resistance function provided by the manufacturer of the temperature sensor 33. Calculate the temperature value (T) using .

The temperature value (T) obtained in this way is input into the image, and if the temperature value (T) is greater than a predetermined value, it is inserted into the warning window.

In addition, by applying a piezo vibration sensor, when the machine tool 1 vibrates and the vibration sensor 32 detects the vibration, the vibration sensor 32 generates a current, and the maximum voltage according to the data sheet of the vibration sensor 32 Since the value (V) exceeds 5V, which is the rated voltage of the AD converter 31, a resistor with a high resistance value is connected to protect the circuit of the AD converter 31.

The voltage value of the vibration sensor 32 acquired during this process is also inputted and output in the image, and, like the temperature value, is inserted into a warning window when the vibration value (V) is greater than a predetermined value.

Additionally, the processed image, data from the temperature sensor 33, and the vibration sensor 32 are streamed and output to at least one monitoring device 23a to 23n at a remote location (steps 250 and 260).

At this time, streaming of video and data is performed by the streaming device 19, and streaming from the streaming device 19 to the monitoring devices 23a to 23n is performed through network equipment 21 capable of network communication.

Figure 3 is a monitor screen of the monitoring devices 23a to 23n on which data obtained from the temperature sensor 33 and the vibration sensor 32 is output. If the temperature is higher than a predetermined value, a warning window is displayed. For example, if the temperature is higher than the predetermined value, a warning window is displayed. A red warning window will appear, and if the vibration value is greater than a certain value, a gray warning window will appear.

In addition, in step 120, data is input in real time from the first proximity sensor 41 installed on the machine tool 1 to the control device 13 in order to determine the processing quantity of the workpiece processed by the machine tool 1. Receive and process. (Step 310)

Then, it is determined whether an interrupt occurred in the data input by the first proximity sensor 41 (320).

In step 120, if an interrupt occurred, counter 1 is added (Count=+1). On the other hand, if an interrupt did not occur, the counter is not added (Count=+1), the counter value is output, and the monitoring device ( It is input to the image processing device 17 to be output in 23a to 23n) (steps 330, 340, and 350).

In steps 310 to 350, the first proximity sensor 41 is turned on when a metal workpiece approaches, and when machining is completed, the workpiece is separated from the machine tool 1 (i.e., the machining operation is completed). (complete) the first proximity sensor 41 is turned off.

When this rise-fall occurs, an interrupt occurs and counter 1 is added.

Through this process, the workpiece production volume (or processing volume) of the machine tool (1) can be estimated.

The data obtained through the processes of steps 310 to 350 are processed through the control device 13, the image processing device 15, and the image processing device 17 and can be confirmed through the monitors of the monitoring devices 23a to 23n. there is.

Figure 4 is a monitor screen of the monitoring devices 23a to 23n where the counter function and time are output.

In addition, in step 120, in order to measure the rotation speed (RPM) of the machine tool 1, the control device 13 receives and processes data in real time from the second proximity sensor 41 installed on the machine tool 1. (Step 410)

Next, it is determined whether an interrupt occurred in the data input by the second proximity sensor 41, and if the interrupt occurred, the rising time and falling time of the second proximity sensor 41 are determined. Record the time between (steps 420 and 430).

In addition, the presence or absence of time records of the rising time and falling time is determined, the RPM of the machine tool 1 is calculated and output, and input to the image processing device 17 to be output to the monitoring devices 23a to 23n. (Steps 440,450)

In this way, a second proximity sensor 41 is provided to check the RPM of the machine tool 1, and when the machine tool 1 rotates once, the second proximity sensor 41 rises once and Set the second proximity sensor 41 so that a fall occurs, and measure the RPM of the tool of the machine tool 1 by measuring the time value between each rise and fall. do.

The RPM value obtained in this way is also input into the video and output.

Figure 5 shows the measured RPM value output on the monitor screen of the monitoring devices 23a to 23n. For example, if the RPM is 30 or less, 0 is output.

And Figure 6 is a photo showing an embodiment in which multi-monitoring is implemented, enabling monitoring of multiple images on a single monitor screen using HTML programming.

The embodiment in Figure 6 shows that two devices are made to output different images.

As described above, in the present invention, the operating machine tool (1) was photographed and the temperature sensor (33) and vibration sensor (32) were applied to the operating machine tool (1) to measure the temperature and vibration level of the operating machine tool (1). .

Therefore, the operating status of the machine tool 1 can be visually determined from a remote location, and when the machine tool 1 rises to a predetermined temperature or vibrates, it is possible to determine whether a specific part (or tool) of the machine tool 1 should be replaced. You can check it.

Likewise, the productivity of the machine tool 1 can be determined through data acquired through the first proximity sensor 41, and the rotation of the machine tool 1 through data acquired through the second proximity sensor 41. You can check whether the machine tool (1) is operating normally by judging the number of revolutions per minute (RPM) or rotation speed.

Through this process, it is eventually possible to check the degree of aging of a specific part (or tool) or whether it should be replaced.

Therefore, there is no need to replace all of the expensive machine tools (1), and the timing of replacement can also be known.

Furthermore, the present invention has the advantage of being able to be implemented using inexpensive devices.

As described above, the present invention has been described with reference to an embodiment shown in the drawings, but this is merely illustrative, and various modifications and equivalent embodiments can be made by those skilled in the art. You will understand.

Therefore, the true scope of protection of the present invention should be determined only by the appended claims.

1. Machine tools
11. Camera
13. Control device
15. Image processing device
17. Image processing device
19. Streaming devices
21. Network equipment
23a~23n. monitoring device
31. AD converter
32. Vibration sensor
33. Temperature sensor

Claims (11)

delete A camera installed on one side of the machine tool to photograph the operating state of the machine tool;
a control device installed on the other side of the machine tool to control and process signals input from the outside, receive an operating image of the machine tool from the camera in real time, and control the image to be output to the outside;
At least one temperature sensor installed on one side of the control device to measure the temperature of the operating machine tool;
At least one vibration sensor is installed on the other side of the control device to measure a vibration state of the operating machine tool;
an AD converter that inputs data from the temperature sensor and the vibration sensor to the control device so that the control device processes and outputs the data;
an image processing device that processes the image received from the control device to be output;
an image processing device that inputs and outputs data output from the AD converter to an image processed by the image processing device;
a streaming device that streams and outputs an image in which data output from the AD converter from the image processing device is input;
At least one monitoring device that outputs the image received by the streaming device to check the operating state of the machine tool and determines whether to replace the machine tool part; includes;
A first proximity sensor is connected to the control device to check the amount of workpiece processing of the machine tool,
The first proximity sensor is turned on when the workpiece approaches, and is turned off when the workpiece leaves the machine tool.
The control device determines that an interrupt has occurred when a rise fall occurs due to the on-off switch, adds counter 1, and adds the workpiece processing amount of the machine tool. According to paragraph 2,
A real-time monitoring system for a machine tool, characterized in that a second proximity sensor is connected to the control device to measure the RPM of the machine tool. According to paragraph 2,
A real-time monitoring system for a machine tool, wherein the temperature sensor includes a thermistor temperature sensor. According to paragraph 2,
A real-time monitoring system for a machine tool, wherein the vibration sensor includes a piezo vibration sensor. delete (a) photographing the operating state of the machine tool with a camera installed on the machine tool;
(b) controlling the control device installed on the machine tool to receive and output an operating image of the machine tool from the camera in real time;
(c) the control device receives the temperature and vibration status of the machine tool in real time from a temperature sensor and a vibration sensor connected to the control device and outputs them together with the image;
(d) image processing the image received from the control device;
(e) calculating a resistance value according to the output temperature of the temperature sensor, calculating the operating temperature of the machine tool using a function of the resistance value and the temperature value, and inputting the result to an image processing device;
(f) inputting data including the temperature input from the image processing device into the image;
(g) inserting a warning window into a warning window when the temperature value (T) input to the image processing device is higher than a predetermined temperature;
(h) determining whether the voltage value (V) of the vibration sensor input to the image processing device is 5V or more, and inserting a warning window if the voltage value (V) is 5V or more;
(i) streaming the image-processed data, the temperature sensor, and the vibration sensor and outputting the data to at least one remote monitoring device;
(j) in step (b), receiving and processing data in real time from a first proximity sensor installed on the machine tool to the control device in order to determine the processing quantity of the workpiece processed by the machine tool;
(k) determining whether an interrupt has occurred in the data input from the first proximity sensor, and if the interrupt has occurred, outputting a count, inputting the output count to the image processing device, and outputting it to the monitoring device. A real-time monitoring method of a machine tool, characterized in that it further includes *;. In clause 7,
(l) in step (b), receiving and processing data in real time from a second proximity sensor installed on the machine tool to the control device to measure the rotational speed (RPM) of the machine tool;
(m) determining whether an interrupt has occurred in the data input by the second proximity sensor, and if the interrupt has occurred, recording the time between the rising time and the falling time of the second proximity sensor;
(n) determining whether there is a time record of the rising time and falling time, calculating and outputting the RPM of the machine tool, inputting it to the image processing device, and outputting it to the monitoring device; further comprising: Characterized by real-time monitoring method of machine tools. In clause 7,
A real-time monitoring method of a machine tool, characterized in that data from the temperature sensor and the vibration sensor are input to the control device through an AD converter. In clause 7,
A real-time monitoring method of a machine tool, wherein the temperature sensor includes a thermistor temperature sensor. In clause 7,
A real-time monitoring method of a machine tool, wherein the vibration sensor includes a piezo vibration sensor.

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