TWI816605B - Cutting process monitoring and perception system and method thereof - Google Patents
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- 238000005520 cutting process Methods 0.000 title claims abstract description 294
- 238000012544 monitoring process Methods 0.000 title claims abstract description 40
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- 238000003754 machining Methods 0.000 claims description 24
- 238000005316 response function Methods 0.000 claims description 14
- 238000006243 chemical reaction Methods 0.000 claims description 6
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Abstract
Description
本發明是有關於一種切削加工監測感知系統及其方法,且特別是於切削工具機進行切削加工時,分析刀具切削及工具機振動情形建立模型,並依據模型透過觸覺及聽覺回饋使用者,實現更高精度的加工即時監測。 The present invention relates to a cutting processing monitoring and sensing system and a method thereof. In particular, when a cutting tool machine is performing cutting processing, it analyzes the tool cutting and machine tool vibration conditions to establish a model, and based on the model, feedback to the user through tactile and auditory feedback is realized. Higher precision real-time monitoring of processing.
目前,金屬切削仍然是最重要的加工過程,為所有工藝產品提供依據。數十年來,人們對切削工藝及其產品質量的要求越來越高,導致切削工藝發生了巨大的變化。 Currently, metal cutting remains the most important machining process, providing the basis for all craft products. Over the past decades, people have placed higher and higher demands on cutting processes and product quality, resulting in dramatic changes in cutting processes.
就目前的技術而言,可能是將感測機制設計於工具機主軸或工作台的方式,以此即時動態力量感測訊號監控刀具加工狀態,所用感測為應變規式感測器,透過監控特定參數以回饋切削控制的方法,於工作臺與工件之間設置感測器偵測切削力,於夾持具上設置感測器偵測旋轉切削力,以統計方法或人工智能演算法預測與判斷其健康狀態,或者進而抑制或避開不佳的加工情形,例如透過調整進給速率或轉速的倍率、顫振等等;這些藉由感測器蒐集之資料進行分析、模擬或預測結果,主要都是以圖形或動畫的方式,讓使用者透 過視覺在螢幕上面觀看,而螢幕通常指的是平面顯示器,亦即是藉由平面顯示器觀看富含3D的內容,透過視覺化的人機介面讓人類使用者觀看模擬結果,但僅透過視覺方式的回饋,對於長時間進行人機加工流程的操作者來說,略顯不足。 As far as the current technology is concerned, it is possible to design the sensing mechanism on the machine tool spindle or workbench to monitor the tool processing status with real-time dynamic force sensing signals. The sensing used is a strain gauge sensor. Through monitoring Specific parameters are used to feed back the cutting control method. Sensors are set up between the workbench and the workpiece to detect the cutting force. Sensors are set up on the holder to detect the rotational cutting force. Statistical methods or artificial intelligence algorithms are used to predict and Determine its health status, or thereby suppress or avoid unfavorable processing conditions, such as by adjusting the feed rate or rotational speed magnification, chatter, etc.; these are analyzed, simulated or predicted through the data collected by the sensors. Mainly in the form of graphics or animation, allowing users to understand Viewed on a screen through vision, and the screen usually refers to a flat-panel display, that is, viewing 3D-rich content through a flat-panel display, allowing human users to view the simulation results through a visual human-machine interface, but only through visual means The feedback is slightly insufficient for operators who perform man-machine processing processes for a long time.
本發明提供一種切削加工監測感知系統,其目的在藉由觸覺或聽覺方式呈現加工狀態,讓使用者透過觸摸或聲音感受加工品質與機台健康狀態。 The present invention provides a cutting processing monitoring and sensing system, which aims to present the processing status through tactile or auditory means, allowing users to feel the processing quality and machine health status through touch or sound.
本發明的一種切削加工監測感知系統,係運作於一切削工具機,該切削加工監測感知系統包括:一切削刀具,設置於該切削工具機,用於切削加工;一加工參數計算單元,設置於該切削工具機,用於取得一加工參數,並計算一幾何接觸情形;一切削力計算單元,設置於該切削工具機,透過該切削刀具計算產生一切削力係數,該切削力係數包括一瞬時靜態切削力及一瞬時動態切削力;一振動訊號擷取單元,設置於該切削工具機,用以感測該切削工具機產生之振動,並產生一振動訊號參數;一形變計算單元,設置於該切削工具機,依據該振動訊號參數,計算出一頻率響應函數,並依據該頻率響應函數,計算出一切削刀具變型量;一模型建構單元,電性連接該加工參數計算單元、該切削力計算單元及該形變計算單元,用以取得該幾何接觸情形、該切削力係數及該切削刀具變型量,並依據該幾何接觸情形、該切削力係數及該切削刀具變型量產生一切削力模型;一觸覺回饋模組,電性連接該模型建構單元,依據該切削力模型,產生一振動回饋; 以及一聽覺回饋模組,電性連接該模型建構單元,依據該切削力模型,產生一聲音回饋,其中,該切削力模型依據該幾何接觸情形、該切削力係數及該切削刀具變型量,計算出該切削刀具與一被切削工件間的該幾何接觸情形,將該切削力係數疊合該切削刀具變型量,成為該切削刀具的一總合變形量,再透過該總合變形量修正該幾何接觸情形,計算產生出該切削力模型。 A cutting processing monitoring and sensing system of the present invention operates on a cutting tool machine. The cutting processing monitoring and sensing system includes: a cutting tool, which is provided on the cutting tool machine and is used for cutting processing; and a processing parameter calculation unit, which is provided on the cutting tool machine. The cutting tool machine is used to obtain a machining parameter and calculate a geometric contact situation; a cutting force calculation unit is provided in the cutting tool machine to calculate and generate a cutting force coefficient through the cutting tool. The cutting force coefficient includes an instantaneous Static cutting force and an instantaneous dynamic cutting force; a vibration signal acquisition unit, installed on the cutting tool machine, for sensing the vibration generated by the cutting tool machine and generating a vibration signal parameter; a deformation calculation unit, installed on the cutting tool machine The cutting tool machine calculates a frequency response function based on the vibration signal parameters, and calculates a cutting tool deformation amount based on the frequency response function; a model construction unit is electrically connected to the processing parameter calculation unit and the cutting force The calculation unit and the deformation calculation unit are used to obtain the geometric contact situation, the cutting force coefficient and the cutting tool deformation amount, and generate a cutting force model based on the geometric contact situation, the cutting force coefficient and the cutting tool deformation amount; A tactile feedback module is electrically connected to the model construction unit and generates a vibration feedback based on the cutting force model; and an auditory feedback module, electrically connected to the model construction unit, to generate an audio feedback based on the cutting force model, wherein the cutting force model calculates based on the geometric contact situation, the cutting force coefficient and the cutting tool deformation amount. The geometric contact situation between the cutting tool and a workpiece to be cut is determined, the cutting force coefficient is superimposed on the deformation amount of the cutting tool to become a total deformation amount of the cutting tool, and then the geometry is corrected through the total deformation amount. In the contact situation, the cutting force model is calculated and generated.
在本發明之一實施例中,上述之加工參數包括切削深度、切削寬度、切削刀刃數、工件材質及主軸轉速。 In one embodiment of the present invention, the above-mentioned processing parameters include cutting depth, cutting width, number of cutting blades, workpiece material and spindle speed.
在本發明之一實施例中,上述之切削力係數為該切削刀具刀尖的實際加工物理量包括扭矩、彎矩及軸向力。 In one embodiment of the present invention, the above-mentioned cutting force coefficient is the actual machining physical quantity of the cutting tool tip, including torque, bending moment and axial force.
在本發明之一實施例中,上述之振動訊號擷取單元為但不限於加速規、光學尺、位移計、速度計其中之一,用以感測該切削工具機於至少一軸向之振動。 In one embodiment of the present invention, the above-mentioned vibration signal acquisition unit is, but is not limited to, one of an accelerometer, an optical ruler, a displacement meter, and a speedometer, and is used to sense the vibration of the cutting tool machine in at least one axial direction. .
在本發明之一實施例中,上述之切削加工監測感知系統更包括一類比數位轉換單元將該振動訊號參數轉換為一數位振動訊號參數傳送至該形變計算單元。 In one embodiment of the present invention, the above-mentioned cutting processing monitoring and sensing system further includes an analog-to-digital conversion unit to convert the vibration signal parameters into a digital vibration signal parameter and transmit it to the deformation calculation unit.
在本發明之一實施例中,上述之切削力係數更包括一平均切削力以及各軸切削力,如X軸切削力、Y軸切削力、Z軸切削力但不限於。 In one embodiment of the present invention, the above-mentioned cutting force coefficient further includes an average cutting force and each axis cutting force, such as X-axis cutting force, Y-axis cutting force, Z-axis cutting force but not limited to.
在本發明之一實施例中,上述之切削力係數包括不考慮該切削刀具刀尖變形與切削工具機於加工過程產生之該振動訊號參數的該瞬時靜態切削力,以及考慮加工過程中造成的該切削刀具刀尖變形和該振動訊號參數的瞬時動態切削力。 In one embodiment of the present invention, the above-mentioned cutting force coefficient includes the instantaneous static cutting force without considering the deformation of the cutting tool tip and the vibration signal parameters generated by the cutting tool machine during the machining process, and taking into account the vibration signal parameters caused during the machining process. The cutting tool tip deformation and the vibration signal parameters are the instantaneous dynamic cutting force.
在本發明之一實施例中,上述之觸覺回饋模組包括:一固定件、至少一觸覺振動器以及一訊號連接單元,透過該固定件將該觸覺回饋模組固定於使用者處,並依據該切削力模型將一振動回饋訊號透過該訊號連接單元,使該至少一觸覺振動器產生該振動回饋。 In one embodiment of the present invention, the above-mentioned tactile feedback module includes: a fixing member, at least one tactile vibrator and a signal connection unit. The tactile feedback module is fixed to the user through the fixing member, and according to The cutting force model transmits a vibration feedback signal through the signal connection unit, causing the at least one tactile vibrator to generate the vibration feedback.
在本發明之一實施例中,上述之聽覺回饋模組包括:一固定件、至少一揚聲器以及一訊號連接單元,透過該固定件將該聽覺回饋模組固定於使用者處,並依據該切削力模型將一聲音回饋訊號透過該訊號連接單元,使該至少一揚聲器產生該聲音回饋。 In one embodiment of the present invention, the above-mentioned auditory feedback module includes: a fixing member, at least one speaker and a signal connection unit. The auditory feedback module is fixed to the user through the fixing member, and according to the cutting The force model passes a sound feedback signal through the signal connection unit to cause the at least one speaker to generate the sound feedback.
在本發明中還包括一種切削加工監測感知方法,係運作於一切削加工監測感知系統,包含下列步驟:通過一人機介面將一加工參數輸入一切削工具機,用以進行切削加工時,執行一加工參數計算程序;通過一加工參數計算單元,取得該加工參數,並計算一幾何接觸情形;通過一切削力計算單元,執行一切削力係數計算程序;依據一切削刀具與一被切削工件之間的夾角的施力或受力,取得一切削力係數;並通過一振動訊號擷取單元,執行一振動訊號計算程序,用以感測該切削工具機產生之振動,並產生一振動訊號參數;通過一形變計算單元,依據該振動訊號參數,計算出一頻率響應函數,並依據該頻率響應函數,計算出一切削刀具變型量;通過一模型建構單元,依據該幾何接觸情形、該切削力係數及該切削刀具變型量產生一切削力模型;以及依據該切削力模型,透過一觸覺回饋模組以及一聽覺回饋模組,分別產生一振動回饋以及一聲音回饋。 The present invention also includes a cutting processing monitoring and sensing method, which is operated in a cutting processing monitoring and sensing system and includes the following steps: inputting a processing parameter into a cutting tool machine through a human-machine interface to perform cutting processing. A machining parameter calculation program; obtains the machining parameters through a machining parameter calculation unit, and calculates a geometric contact situation; executes a cutting force coefficient calculation program through a cutting force calculation unit; based on the relationship between a cutting tool and a workpiece to be cut The force applied or received at the included angle is used to obtain a cutting force coefficient; and a vibration signal calculation program is executed through a vibration signal acquisition unit to sense the vibration generated by the cutting tool machine and generate a vibration signal parameter; Through a deformation calculation unit, a frequency response function is calculated based on the vibration signal parameters, and a cutting tool deformation amount is calculated based on the frequency response function; through a model construction unit, based on the geometric contact situation, the cutting force coefficient And the cutting tool deformation quantity generates a cutting force model; and based on the cutting force model, a vibration feedback and a sound feedback are generated respectively through a tactile feedback module and an auditory feedback module.
本發明的效果在於,本切削加工監測感知系統藉由刀具的總合變形量修正切削刀具和被切削工件之間的幾何接觸情形(CWE),從而計算 出動態的切削力量,動態的切削力量除了可以一般的平面顯示器顯示方式,更可以將切削力量透過觸覺或聽覺或兩者融合並可以整合與視覺化的綜合方式呈現,觸覺的顯示方式有諸多方式,例如,可以透過電氣方式經由震動馬達呈現、透過電磁轉換成磁力呈現、以及透過機械方式經由彈簧變形力量呈現等等,然後經由人手或身體皮膚接觸或非接觸而感知,也可以透過聲波(或骨傳導等等)的方式傳導,透過喇叭傳出經由人耳接收等等,有著更加的產業利用性。 The effect of the present invention is that the cutting processing monitoring and sensing system corrects the geometric contact situation (CWE) between the cutting tool and the workpiece by using the total deformation of the tool, thereby calculating Dynamic cutting force can be displayed in a general flat-panel display. The cutting force can also be displayed through touch or hearing, or a comprehensive way of integrating and visualizing the cutting force. There are many ways to display tactile force. , for example, it can be presented electrically through a vibration motor, through electromagnetic conversion into magnetic force, and mechanically through spring deformation force, etc., and then sensed through human hands or body skin contact or non-contact, or through sound waves (or Bone conduction, etc.) are transmitted through speakers and received by human ears, etc., which have greater industrial applicability.
11:切削刀具 11:Cutting tools
12:加工參數計算單元 12: Processing parameter calculation unit
13:切削力計算單元 13: Cutting force calculation unit
14:振動訊號擷取單元 14:Vibration signal acquisition unit
15:形變計算單元 15: Deformation calculation unit
16:模型建構單元 16:Model building unit
17:觸覺回饋模組 17: Tactile feedback module
18:聽覺回饋模組 18: Auditory feedback module
S210~S280:步驟流程 S210~S280: step process
圖1是根據本發明之一種切削加工監測感知系統的方塊圖。 Figure 1 is a block diagram of a cutting processing monitoring and sensing system according to the present invention.
圖2是根據本發明之一種切削加工監測感知方法的步驟流程圖。 Figure 2 is a step flow chart of a cutting process monitoring and sensing method according to the present invention.
圖3是根據本發明之一種切削加工監測感知方法的切削力係數計算程序示意圖。 Figure 3 is a schematic diagram of a cutting force coefficient calculation program according to a cutting process monitoring and sensing method of the present invention.
圖4是根據本發明之一種切削加工監測感知方法的振動訊號計算示意圖。 Figure 4 is a schematic diagram of vibration signal calculation according to a cutting process monitoring and sensing method according to the present invention.
為讓本發明之上述特徵和優點能更明顯易懂,下文特舉實施例,並配合所附圖式,除了這些詳細說明之外,本發明亦可廣泛地施行於其它的實施例中,任何所述實施例的輕易替代、修改、等效變化都包含在本發明之範圍內,並以申請專利範圍為準。在說明書的描述中,為了使讀 者對本發明有較完整的瞭解,提供了許多特定細節;然而,本發明可能在省略部分或全部特定細節的前提下,仍可實施。此外,眾所周知的步驟或元件並未描述於細節中,以避免對本發明形成不必要之限制。圖式中相同或類似之元件將以相同或類似符號來表示。特別注意的是,圖式僅為示意之用,並非代表元件實際之尺寸或數量,有些細節可能未完全繪出,以求圖式之簡潔,作詳細說明如下。 In order to make the above-mentioned features and advantages of the present invention more clearly understood, the following embodiments are illustrated in conjunction with the accompanying drawings. In addition to these detailed descriptions, the present invention can also be widely implemented in other embodiments. Easy substitutions, modifications, and equivalent changes of the embodiments are included in the scope of the present invention, and are subject to the scope of the patent application. In the description of the manual, in order to make readers Many specific details are provided to provide a more complete understanding of the invention; however, the invention may be practiced without some or all of the specific details. In addition, well-known steps or elements are not described in detail to avoid unnecessary limitations on the present invention. The same or similar elements in the drawings will be represented by the same or similar symbols. Please note that the drawings are for illustrative purposes only and do not represent the actual size or quantity of components. Some details may not be fully drawn in order to keep the drawings concise. Detailed descriptions are as follows.
請參照圖1,圖1是根據本發明之一種切削加工監測感知系統的方塊圖。在本實施例中的一種切削加工監測感知系統,係運作於一切削工具機,該切削加工監測感知系統包括:一切削刀具11,設置於該切削工具機,用於切削加工;一加工參數計算單元12,設置於該切削工具機,用於取得一加工參數,並計算一幾何接觸情形;一切削力計算單元13,設置於該切削工具機,透過該切削刀具11計算產生一切削力係數,該切削力係數包括一瞬時靜態切削力及一瞬時動態切削力;一振動訊號擷取單元14,設置於該切削工具機,用以感測該切削工具機產生之振動,並產生一振動訊號參數;一形變計算單元15,設置於該切削工具機,依據該振動訊號參數,計算出一頻率響應函數,並依據該頻率響應函數,計算出一切削刀具變型量;一模型建構單元16,電性連接該加工參數計算單元12、該切削力計算單元13及該形變計算單元15,用以取得該幾何接觸情形、該切削力係數及該切削刀具變型量,並依據該幾何接觸情形、該切削力係數及該切削刀具變型量產生一切削力模型;一觸覺回饋模組17,電性連接該模型建構單元16,依據該切削力模型,產生一振動回饋;以及一聽覺回饋模組18,電性連接該模型建構單元16,依據該切削力模型,產生一聲音回饋,其中, 該切削力模型依據該幾何接觸情形、該切削力係數及該切削刀具變型量,計算出該切削刀具11與一被切削工件間的該幾何接觸情形,將該切削力係數疊合該切削刀具變型量,成為該切削刀具11的一總合變形量,再透過該總合變形量修正該幾何接觸情形,計算產生出該切削力模型。 Please refer to Figure 1, which is a block diagram of a cutting processing monitoring and sensing system according to the present invention. In this embodiment, a cutting processing monitoring and sensing system operates on a cutting tool machine. The cutting processing monitoring and sensing system includes: a cutting tool 11, which is provided on the cutting tool machine for cutting processing; a processing parameter calculation Unit 12 is provided in the cutting tool machine and is used to obtain a machining parameter and calculate a geometric contact situation; a cutting force calculation unit 13 is provided in the cutting tool machine to calculate and generate a cutting force coefficient through the cutting tool 11. The cutting force coefficient includes an instantaneous static cutting force and an instantaneous dynamic cutting force; a vibration signal acquisition unit 14 is provided on the cutting tool machine to sense the vibration generated by the cutting tool machine and generate a vibration signal parameter ; A deformation calculation unit 15, provided in the cutting tool machine, calculates a frequency response function based on the vibration signal parameters, and calculates a cutting tool deformation amount based on the frequency response function; a model construction unit 16, electrically The machining parameter calculation unit 12, the cutting force calculation unit 13 and the deformation calculation unit 15 are connected to obtain the geometric contact situation, the cutting force coefficient and the cutting tool deformation amount, and based on the geometric contact situation, the cutting force The coefficients and the cutting tool deformation amount generate a cutting force model; a tactile feedback module 17 is electrically connected to the model construction unit 16, and generates a vibration feedback based on the cutting force model; and an auditory feedback module 18 is electrically Connect the model construction unit 16 to generate a sound feedback based on the cutting force model, where, The cutting force model calculates the geometric contact situation between the cutting tool 11 and a cut workpiece based on the geometric contact situation, the cutting force coefficient and the cutting tool deformation, and superimposes the cutting force coefficient with the cutting tool deformation. The amount becomes a total deformation amount of the cutting tool 11, and then the geometric contact situation is corrected by the total deformation amount, and the cutting force model is calculated and generated.
作為優選方式,該加工參數包括切削深度、切削寬度、切削刀刃數、工件材質及主軸轉速。 As a preferred method, the processing parameters include cutting depth, cutting width, number of cutting blades, workpiece material and spindle speed.
作為優選方式,該切削力係數為該切削刀具11刀尖的實際加工物理量包括扭矩、彎矩及軸向力。 As a preferred way, the cutting force coefficient is the actual machining physical quantity of the cutting tool 11 tip, including torque, bending moment and axial force.
作為優選方式,該振動訊號擷取單元14為但不限於加速規、光學尺、位移計、速度計其中之一,用以感測該切削工具機於至少一軸向之振動。 As a preferred method, the vibration signal acquisition unit 14 is, but is not limited to, one of an accelerometer, an optical ruler, a displacement meter, and a speedometer, and is used to sense the vibration of the cutting tool machine in at least one axial direction.
作為優選方式,該切削加工監測感知系統更包括一類比數位轉換單元將該振動訊號參數轉換為一數位振動訊號參數傳送至該形變計算單元15。 As a preferred method, the cutting processing monitoring and sensing system further includes an analog-to-digital conversion unit to convert the vibration signal parameters into a digital vibration signal parameter and transmit it to the deformation calculation unit 15 .
作為優選方式,該切削力係數更包括一平均切削力以及各軸切削力,如X軸切削力、Y軸切削力、Z軸切削力但不限於。 As a preferred method, the cutting force coefficient further includes an average cutting force and each axis cutting force, such as X-axis cutting force, Y-axis cutting force, Z-axis cutting force but not limited to.
作為優選方式,該切削力係數包括不考慮該切削刀具11刀尖變形與切削工具機於加工過程產生之該振動訊號參數的該瞬時靜態切削力,以及考慮加工過程中造成的該切削刀具11刀尖變形和該振動訊號參數的瞬時動態切削力。 As a preferred method, the cutting force coefficient includes the instantaneous static cutting force without taking into account the deformation of the cutting tool tip 11 and the vibration signal parameters generated by the cutting tool machine during the machining process, and takes into account the cutting force of the cutting tool 11 caused during the machining process. The tip deformation and the instantaneous dynamic cutting force of the vibration signal parameters.
作為優選方式,該觸覺回饋模組17包括:一固定件、至少一觸覺振動器以及一訊號連接單元,透過該固定件將該觸覺回饋模組17固定 於使用者處,並依據該切削力模型將一振動回饋訊號透過該訊號連接單元,使該至少一觸覺振動器產生該振動回饋。 As a preferred method, the tactile feedback module 17 includes: a fixing member, at least one tactile vibrator and a signal connection unit, and the tactile feedback module 17 is fixed through the fixing member. At the user's location, a vibration feedback signal is passed through the signal connection unit according to the cutting force model, so that the at least one tactile vibrator generates the vibration feedback.
作為優選方式,該聽覺回饋模組18包括:一固定件、至少一揚聲器以及一訊號連接單元,透過該固定件將該聽覺回饋模組18固定於使用者處,並依據該切削力模型將一聲音回饋訊號透過該訊號連接單元,使該至少一揚聲器產生該聲音回饋。 As a preferred method, the auditory feedback module 18 includes: a fixing member, at least one speaker and a signal connection unit. The auditory feedback module 18 is fixed to the user through the fixing member, and a The sound feedback signal passes through the signal connection unit, causing the at least one speaker to generate the sound feedback.
請同時參照圖2-圖4,圖2是根據本發明之一種切削加工監測感知方法的步驟流程圖;圖3是根據本發明之一種切削加工監測感知方法的切削力係數計算程序示意圖;圖4是根據本發明之一種切削加工監測感知方法的振動訊號計算示意圖。在圖2中的一種切削加工監測感知方法,係運作於一切削加工監測感知系統,包含下列步驟:步驟S210:通過人機介面將加工參數輸入切削工具機,用以進行切削加工時,執行加工參數計算程序;步驟S220:通過加工參數計算單元,取得該加工參數,並計算幾何接觸情形;步驟S230:通過切削力計算單元,執行切削力係數計算程序;步驟S240:依據切削刀具與被切削工件之間的夾角的施力或受力,取得切削力係數;步驟S250:通過振動訊號擷取單元,執行振動訊號計算程序,用以感測該切削工具機產生之振動,並產生振動訊號參數;步驟S260:通過形變計算單元,依據該振動訊號參數,計算出頻率響應函數,並依據該頻率響應函數,計算出切削刀具變型量; 步驟S270:通過模型建構單元,依據該幾何接觸情形、該切削力係數及該切削刀具變型量產生切削力模型;步驟S280:依據該切削力模型,透過觸覺回饋模組以及聽覺回饋模組,分別產生振動回饋以及聲音回饋。 Please refer to Figures 2-4 at the same time. Figure 2 is a step flow chart of a cutting process monitoring and sensing method according to the present invention; Figure 3 is a schematic diagram of a cutting force coefficient calculation program according to a cutting process monitoring and sensing method of the present invention; Figure 4 It is a schematic diagram of vibration signal calculation according to a cutting processing monitoring and sensing method according to the present invention. A cutting processing monitoring and sensing method in Figure 2 operates on a cutting processing monitoring and sensing system and includes the following steps: Step S210: Input processing parameters into the cutting tool machine through the human-machine interface to perform processing during cutting. Parameter calculation program; Step S220: Obtain the processing parameters through the machining parameter calculation unit, and calculate the geometric contact situation; Step S230: Execute the cutting force coefficient calculation program through the cutting force calculation unit; Step S240: According to the cutting tool and the workpiece to be cut The cutting force coefficient is obtained by exerting or receiving force at the included angle; step S250: execute the vibration signal calculation program through the vibration signal acquisition unit to sense the vibration generated by the cutting tool machine and generate vibration signal parameters; Step S260: Calculate the frequency response function based on the vibration signal parameters through the deformation calculation unit, and calculate the cutting tool deformation amount based on the frequency response function; Step S270: Generate a cutting force model through the model construction unit according to the geometric contact situation, the cutting force coefficient and the cutting tool deformation amount; Step S280: Based on the cutting force model, through the tactile feedback module and the auditory feedback module, respectively Produce vibration feedback and sound feedback.
於本實施例中,通過人機介面將加工參數輸入切削工具機時,通過加工參數計算單元解譯人為編寫或者使用CAM軟體產生的加工參數,其中該加工參數可為數值控制程式碼(NC Codes,Numerical Control Codes),用以計算切削刀具和被切削工件之間的幾何接觸情形(CWE,Cutter-Workpiece Engagement)。 In this embodiment, when machining parameters are input into the cutting tool machine through the human-machine interface, the machining parameter calculation unit interprets the machining parameters written manually or generated using CAM software, where the machining parameters can be numerical control program codes (NC Codes). , Numerical Control Codes), used to calculate the geometric contact situation between the cutting tool and the workpiece being cut (CWE, Cutter-Workpiece Engagement).
其中,該加工參數包括切削深度、切削寬度、切削刀刃數、工件材質及主軸轉速。 Among them, the processing parameters include cutting depth, cutting width, number of cutting edges, workpiece material and spindle speed.
如圖3所示,於本實施例中,切削力係數計算程序係依據切削過程的切削力數據,計算出切削力係數(CFC,Cutting Force Coefficients),建立切削力係數資料庫(CFC DB)。 As shown in Figure 3, in this embodiment, the cutting force coefficient calculation program calculates the cutting force coefficients (CFC, Cutting Force Coefficients) based on the cutting force data of the cutting process, and establishes a cutting force coefficient database (CFC DB).
其中,該切削力係數為該切削刀具刀尖的實際加工物理量包括扭矩、彎矩及軸向力。 Among them, the cutting force coefficient is the actual machining physical quantity of the cutting tool tip, including torque, bending moment and axial force.
其中,該切削力係數更包括一平均切削力以及各軸切削力,如X軸切削力、Y軸切削力、Z軸切削力但不限於。 Among them, the cutting force coefficient further includes an average cutting force and each axis cutting force, such as X-axis cutting force, Y-axis cutting force, Z-axis cutting force but not limited to.
其中,該切削力係數包括不考慮該切削刀具刀尖變形與切削工具機於加工過程產生之該振動訊號參數的該瞬時靜態切削力,以及考慮加工過程中造成的該切削刀具刀尖變形和該振動訊號參數的瞬時動態切削力。 Wherein, the cutting force coefficient includes the instantaneous static cutting force without considering the deformation of the cutting tool tip and the vibration signal parameters generated by the cutting tool machine during the machining process, and taking into account the deformation of the cutting tool tip and the Vibration signal parameters of instantaneous dynamic cutting force.
如圖4所示,於本實施例中,振動訊號計算程序係經由分析振動訊號擷取單元蒐集機台的振動訊號,如使用傅立葉轉換(Fast Fourier Transformation)將時域(Time Domain)振動訊號轉成頻率域(Frequency Domain)的頻率響應函數(FRF,Frequency Response Function)。 As shown in Figure 4, in this embodiment, the vibration signal calculation program collects the vibration signal of the machine through the analysis vibration signal acquisition unit, such as using Fast Fourier Transformation to convert the time domain vibration signal into into the frequency response function (FRF, Frequency Response Function) of the frequency domain (Frequency Domain).
再經由梁柱分析(Beam Analysis)、子結構偶合分析(RCSA,Receptance Coupling Substructure Analysis)、模態分析(Modal Analysis)等,計算切削刀具變形量。 Then through beam analysis (Beam Analysis), substructure coupling analysis (RCSA, Receptance Coupling Substructure Analysis), modal analysis (Modal Analysis), etc., the cutting tool deformation is calculated.
其中,該振動訊號擷取單元為但不限於加速規、光學尺、位移計、速度計其中之一,用以感測該切削工具機於至少一軸向之振動。 The vibration signal acquisition unit is, but is not limited to, one of an accelerometer, an optical ruler, a displacement meter, and a speedometer, and is used to sense the vibration of the cutting tool machine in at least one axial direction.
其中,該切削加工監測感知系統更包括一類比數位轉換單元將該振動訊號參數轉換為一數位振動訊號參數傳送至該形變計算單元。 Among them, the cutting processing monitoring and sensing system further includes an analog-to-digital conversion unit to convert the vibration signal parameters into a digital vibration signal parameter and transmit it to the deformation calculation unit.
綜上所述,本切削加工監測感知系統主要是將該切削力量透過觸覺或聽覺或兩者融合並可以整合與視覺化的綜合方式呈現。觸覺的顯示方式有諸多方式,例如,可以透過電氣方式經由震動馬達呈現、透過電磁轉換成磁力呈現、以及透過機械方式經由彈簧變形力量呈現等等,然後經由人手或身體皮膚接觸或非接觸而感知,也可以透過聲波(或骨傳導等等)的方式傳導,透過喇叭傳出經由人耳接收等等,有著更加的產業利用性。 To sum up, this cutting processing monitoring and sensing system mainly presents the cutting force through touch or hearing or a combination of both, and can be integrated and visualized in a comprehensive way. There are many ways to display tactile sensations. For example, it can be displayed electrically through a vibration motor, through electromagnetic conversion into magnetic force, and mechanically through the deformation force of a spring. It can then be sensed through human hands or body skin contact or non-contact. , it can also be transmitted through sound waves (or bone conduction, etc.), transmitted through speakers and received by human ears, etc., which has greater industrial applicability.
雖然本發明以前述實施例揭露如上,然其並非用以限定本發明,任何熟習相像技藝者,在不脫離本發明之精神和範圍內,所作更動與潤飾之等效替換,仍為本發明之專利保護範圍內。 Although the present invention is disclosed in the foregoing embodiments, they are not intended to limit the present invention. Any person skilled in the similar art can make equivalent changes and modifications without departing from the spirit and scope of the present invention. Within the scope of patent protection.
S210~S280:步驟流程 S210~S280: step process
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