WO2018232858A1 - 一种机床运行状态的智能监控方法及系统 - Google Patents

一种机床运行状态的智能监控方法及系统 Download PDF

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Publication number
WO2018232858A1
WO2018232858A1 PCT/CN2017/096339 CN2017096339W WO2018232858A1 WO 2018232858 A1 WO2018232858 A1 WO 2018232858A1 CN 2017096339 W CN2017096339 W CN 2017096339W WO 2018232858 A1 WO2018232858 A1 WO 2018232858A1
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Prior art keywords
fault
machine tool
running
repair
type
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PCT/CN2017/096339
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English (en)
French (fr)
Inventor
杜光东
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深圳市盛路物联通讯技术有限公司
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Publication of WO2018232858A1 publication Critical patent/WO2018232858A1/zh

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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by monitoring or safety
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31439—Alarms can be warning, alert or fault

Definitions

  • the invention relates to the field of industrial intelligent monitoring, in particular to an intelligent monitoring method for an operating state of a machine tool and an intelligent monitoring system.
  • the numerical control sensor network system For the monitoring of the working state of the machine tool, the numerical control sensor network system is usually used.
  • the sensor and the processor are usually connected by wired or wireless connection, and the working state of the machine tool is monitored.
  • the staff is reminded by the sound and light alarm light.
  • This method can not effectively analyze the fault of the machine tool. It is impossible to know which machine is prone to any problem.
  • the intelligence judges or manually records the faults of each machine tool. When the number of machine tools is large, the method of manual recording is used. There are great limitations and inconveniences.
  • the technical problem to be solved by the present invention is to provide an intelligent monitoring method and an intelligent monitoring system for monitoring the running state of the machine tool in view of the deficiencies of the prior art in monitoring the running condition of the machine tool.
  • An intelligent monitoring method for the running state of a machine tool includes the following steps:
  • Step 1 monitoring the running state of the machine tool, and when monitoring the running fault of the machine tool, determining the type of the running fault;
  • Step 2 Match corresponding fault information from a preset running fault database according to the type of the running fault
  • Step 3 When the corresponding fault information is matched in the running fault database, it is determined whether the running fault can be automatically repaired;
  • Step 4 When the operation fault can be automatically repaired, the operation fault is automatically repaired.
  • the invention has the beneficial effects that the intelligent monitoring method for the running state of the machine tool provided by the invention determines the type of the fault occurring during the running of the machine tool and performs the fault information in the preset running fault database. Matching and judging whether the fault can be automatically repaired, and realizing the automatic repair of the running fault when the running fault can be automatically repaired, which can reduce the work intensity of the maintenance personnel, improve the repair efficiency, and make the machine tool timely after the fault occurs.
  • the ground is automatically repaired to reduce the damage caused by the fault.
  • the present invention can also be improved as follows.
  • the intelligent monitoring method further includes the following steps:
  • An automated fixer library is built that contains a variety of fixes for repairing the operational failure.
  • step 4 the automatic repair of the operation fault is specifically:
  • the operational failure is repaired by invoking the fix in the automatic fix library.
  • the operation failure can be automatically repaired in time to reduce the loss caused by the failure.
  • An intelligent monitoring system for the running state of a machine tool comprising:
  • Monitoring device for monitoring the operating state of the machine tool
  • a processor configured to determine a type of the operation fault when an operational failure occurs in the machine tool
  • a communication device configured to match corresponding fault information from a preset operational fault database according to the type of the operational fault
  • the processor is further configured to: when the corresponding fault information is matched in the running fault database, determine whether the running fault can be automatically repaired;
  • the invention provides an intelligent monitoring system for the running state of the machine tool, which judges the type of failure occurring during the running of the machine tool by the processor, and matches the fault information in the preset running fault database, and whether the fault can be automatically
  • the repair judges and realizes that when the operation fault can be automatically repaired, the operation fault is automatically repaired, the work intensity of the maintenance personnel can be reduced, the repair efficiency is improved, and the machine tool can automatically repair in time after the fault occurs, thereby reducing the fault due to the fault.
  • the present invention can also be improved as follows.
  • the intelligent monitoring system further includes:
  • a fix acquisition device for obtaining a fix
  • a fix associated device for associating the fix with the operational failure that the fix is capable of repairing
  • An automated hotfix library that stores a variety of fixes for repairing the operational failure.
  • the automatic repair program stores a repair program.
  • the corresponding repair program can be automatically repaired in time to reduce the damage caused by the fault.
  • the operational failure is repaired by invoking the fix in the automatic fix library.
  • the processor can automatically repair the running fault in time and reduce the loss caused by the fault by calling the corresponding repair program from the automatic repair library.
  • FIG. 1 is a schematic flow chart of an intelligent monitoring method for a running state of a machine tool according to an embodiment of the present invention
  • FIG. 2 is a flowchart of an intelligent monitoring method for a running state of a machine tool according to another embodiment of the present invention
  • FIG. 3 is a flowchart of an intelligent monitoring method for a running state of a machine tool according to another embodiment of the present invention.
  • FIG. 4 is a flowchart of an intelligent monitoring method for a running state of a machine tool according to another embodiment of the present invention.
  • FIG. 5 is a flowchart of an intelligent monitoring method for a running state of a machine tool according to another embodiment of the present invention.
  • FIG. 6 is a flowchart of an intelligent monitoring method for a running state of a machine tool according to another embodiment of the present invention.
  • FIG. 7 is an interaction timing diagram of an intelligent monitoring method for a running state of a machine tool according to another embodiment of the present invention.
  • FIG. 8 is a structural structural diagram of an intelligent monitoring system for operating state of a machine tool according to another embodiment of the present invention.
  • FIG. 9 is a structural diagram of an intelligent monitoring system for operating state of a machine tool according to another embodiment of the present invention.
  • FIG. 10 is a structural diagram of an intelligent monitoring system for operating state of a machine tool according to another embodiment of the present invention.
  • FIG. 11 is a connection diagram of an intelligent monitoring system for operating state of a machine tool according to another embodiment of the present invention.
  • FIG. 12 is a network topology diagram of an intelligent monitoring system for operating state of a machine tool according to another embodiment of the present invention.
  • FIG. 1 is a schematic flowchart diagram of an intelligent monitoring method for a running state of a machine tool according to an embodiment of the present invention, where the method includes the following steps:
  • the intelligent monitoring method for the running state of the machine tool determines the fault type occurring during the running of the machine tool, and matches the fault information in the preset running fault database, and whether the fault can be automatically
  • the repair judges and realizes that when the operation fault can be automatically repaired, the operation fault is automatically repaired, the work intensity of the maintenance personnel can be reduced, the repair efficiency is improved, and the machine tool can automatically repair in time after the fault occurs, thereby reducing the fault due to the fault.
  • another embodiment of the present invention provides an intelligent monitoring method for operating state of a machine tool, which may further include the following steps:
  • the fix here is the software or program that automatically repairs the software running error, and can also fix some hardware errors.
  • the error can be fixed according to the preset parameters.
  • the repair can be implemented by restarting the machine tool, then the repair program can be set to restart the machine tool, and the implementation manner can be implemented by software control or by controlling the machine;
  • the automatic fix library contains various fixes for repairing the running fault.
  • the fix stored in the automatic fix library here may be a type of running fault corresponding to a type of repair, or may be a kind of The fix corresponds to multiple faults.
  • the corresponding repair program can be quickly called from the automatic repair program library, and the operation failure can be automatically repaired in time to reduce the loss caused by the failure.
  • step S104 the automatic repair of the running fault may specifically be:
  • Repairing a running fault by calling a fix in the auto-repair library, for example, when a fault occurs, analyzing the type of fault that results in the fault, matches the type of the fault with the fix in the auto-repair library,
  • the repair program can be automatically called to repair the machine's running fault.
  • the intelligent monitoring method for the running state of the machine tool provided in the embodiment can automatically repair the running fault in time by reducing the fault caused by the fault by calling the corresponding repairing program from the automatic repairing program library.
  • FIG. 2 is a flowchart of a method for intelligently monitoring an operating state of a machine tool according to another embodiment of the present invention.
  • a fault that cannot be automatically repaired may be processed, specifically including The following steps:
  • monitoring the running state of the machine tool when monitoring the machine running fault, judging the type of running fault
  • the machine tool here can be understood as the CNC machine in the usual sense, monitoring its running state, referring to its The normal working state is monitored.
  • the working state is different from the normal working state, it is judged that the machine tool has an operation failure, and according to the performance form of the running fault, the type of the fault of the machine tool can be judged;
  • the monitoring of the operating state of the machine tool can be divided into software monitoring and hardware monitoring, wherein the software monitoring detects the working state of the machine tool by monitoring the setting parameters or the control system of the machine tool;
  • the hardware monitoring detects the working state of the machine tool by the physical quantity such as temperature, current or vibration of the machine tool. For example, it can be monitored by a temperature sensor, a video monitor, an image processor, etc.
  • the running fault can be detected by a pre-written test program.
  • the analysis program automatically collects and analyzes the characteristics of the running fault, and determines the type of the operating fault according to the characteristics of the operating fault, for example, when the machine tool appears In the case of a crash, the characteristic is that the software and the machine tool do not respond, so it can be determined that the fault is a crash, and on this basis, the characteristics of each fault can be classified and identified;
  • the fault type of the machine tool can be determined according to a pre-written test program
  • the running fault includes mechanical fault, electrical fault, system fault, etc., which cannot make the machine tool continue to work normally;
  • S202 Match corresponding fault information from a preset operation fault database according to the type of the operation fault. For example, when it is detected that the machine vibration is too severe and exceeds the threshold, the matching from the running fault database is caused by the operation fault of the machine tool being severe. Corresponding fault type;
  • S203 when matching the corresponding fault information in the running fault database, according to the matching result, determining whether the running fault can be automatically repaired, and when the running fault can be automatically repaired, executing S204, when the running fault cannot be automatically repaired, executing S205, For example, if the fault type of the machine is stored in the running fault database, then when the machine vibration is detected to be too severe, the corresponding fault information can be matched from the running fault database, and then the machine tool is stored according to the running fault database. Whether the vibration type is severe, whether the fault type can be automatically repaired, and whether the fault type of the machine vibration is severe can be automatically repaired;
  • S205 sending, to the preset receiving end, first repairing information for informing the maintenance personnel to manually repair the running fault, for example, when detecting a circuit board of the machine tool by detecting the circuit board of the machine tool, the circuit is damaged.
  • the type of failure of the board is matched with the fault information in the running fault database. It is found that this fault cannot be repaired by automatic repair. It is necessary to manually replace the damaged board with a new one. Therefore, send the circuit to the maintenance personnel. The board is damaged and this fault is notified of manual repair.
  • the intelligent monitoring method for the running state of the machine tool provided in the embodiment is matched with the fault information in the preset running fault database by the type of the running fault to determine whether the fault can be automatically repaired. It fixes simple faults, reduces the workload of maintenance personnel, and notifies maintenance personnel when it is unable to automatically repair operational faults, improving repair efficiency.
  • a flowchart of an intelligent monitoring method for a running state of a machine tool may further perform a fault that does not match a corresponding fault type based on the foregoing embodiment. Processing includes the following steps:
  • S302 Match the corresponding fault information from the preset running fault database according to the type of the running fault, and determine whether the corresponding fault information can be matched in the running fault database, when the corresponding fault information is not matched in the running fault database.
  • S303 when matching the corresponding fault information in the running fault database, executing S304;
  • the repair method is to replace the new circuit board, and the repair method is to replace the new circuit board.
  • the repair method is to call the machine search system's own block search function to check and repair the fault;
  • S308 determining whether the repair mode can be implemented by automatic repair, and obtaining a judgment result. For example, in the example of the previous step, when the fault is caused by the circuit board being burned, the repair method is to replace the new circuit board, and the judgment is found by the judgment.
  • the repair method cannot be realized by automatic repair of the system. It needs to be repaired manually by the maintenance personnel. When the fault is caused by the user's program error, the maintenance personnel can check it and find that the block search function provided by the machine system can check. Fix all errors, so by judging that this repair method can be achieved through automatic system repair;
  • the intelligent monitoring method for the running state of the machine tool determines the type and repair mode after repairing the unknown running error, and stores it in the running fault database, so that the next error occurs. This type of error can be identified and processed, improving the efficiency of handling faults.
  • FIG. 4 is a flowchart of an intelligent monitoring method for operating state of a machine tool according to another embodiment of the present invention. Based on the foregoing embodiment, information about running faults may also be collected and stored. Includes the following steps:
  • S402 Match the corresponding fault information from the preset running fault database according to the type of the running fault, and determine whether the corresponding fault information can be matched in the running fault database, when the corresponding fault information is not matched in the running fault database. , executing S403, when matching the corresponding fault information in the running fault database, executing S404;
  • each machine tool can have a dedicated record table to record the fault of the machine, or to create a record table according to the type of fault, and the time and machine number of the fault will be recorded and recorded in it. Or, you can count the errors that occur on each machine in the same record table. Easy to view.
  • the intelligent monitoring method for the running state of the machine tool provided in the embodiment is to repair the fault occurring during the running of the machine tool, and after the fault is repaired, the type of the fault, the number of the machine tool and the repair time are performed. Storage makes it easy to analyze the cause of the malfunction and the machine that is prone to failure.
  • FIG. 5 it is a flowchart of an intelligent monitoring method for a running state of a machine tool according to another embodiment of the present invention.
  • the smart monitoring method may further include the following steps:
  • S502 Match the corresponding fault information from the preset running fault database according to the type of the running fault, and determine whether the corresponding fault information can be matched in the running fault database, when the corresponding fault information is not matched in the running fault database.
  • S503 when matching the corresponding fault information in the running fault database, executing S504;
  • S511 Perform statistical analysis on the time, type and quantity of the running fault of the machine tool according to the running fault record table.
  • Alarm information for example, taking a machine tool A and machine tool B as an example, establishing an operation fault record table of machine tool A and machine tool B, respectively, for the time when the machine tool A and the machine tool B are in operation failure in the first quarter from January to March, The type and quantity were collected and found that in the first quarter, machine A only experienced one failure, which was a random failure.
  • Random failure refers to the failure of occasional or secondary occurrence under the same conditions, such as grinding grooves.
  • the position of the machine has changed, and the machine B has experienced many failures.
  • the machine B is a CNC lathe that uses the FANUC 0iTC system.
  • the lathe has 10 times of 417 alarms.
  • the corresponding repair method is to modify the parameter NO: 2023.
  • the preset value of the number of running faults can be set to 5 times, and the machine tool A and the machine tool B are respectively judged, and it is found that the number of faults of the machine tool A is less than 5 times, and the machine tool B is out. 5 417 times greater than the alarm time, and therefore, prone to the machine B 417 transmits alarm information to the maintenance personnel for maintenance of the machine B by service personnel.
  • an operation failure model can be established for each machine tool according to the operation failure record table, and the type, quantity and frequency of each machine tool failure are analyzed, and each machine tool is scored, so as to accurately grasp and evaluate the operation of the machine tool. State and quality of machine work.
  • the intelligent monitoring method for the running state of the machine tool determines the fault type occurring during the running of the machine tool, and matches the fault information in the preset running fault database, and whether the fault can be automatically
  • the repair judges and realizes that when the operation fault can be automatically repaired, the operation fault is automatically repaired, the work intensity of the maintenance personnel can be reduced, the repair efficiency is improved, and the machine tool can automatically repair in time after the fault occurs, thereby reducing the fault due to the fault.
  • FIG. 6 is a flowchart of an intelligent monitoring method for operating state of a machine tool according to another embodiment of the present invention. Based on the foregoing embodiment, a specific example is used to illustrate that when an operation fault is detected, The flow of the intelligent monitoring method is taken as an example of a CNC grinding machine made by the German SIEMENS 810 system.
  • the intelligent monitoring method comprises the following steps:
  • the numerical control grinder After receiving the task of making the nut, the numerical control grinder starts working, and the nut is polished according to the input procedure.
  • the numerical control grinder starts to start, the production process is monitored, and during the production process, the automatic grinding of a numerical control grinder is found. The machining cannot be carried out continuously. After grinding a nut, the spindle grinding wheel is not retracted and the automatic cycle is terminated.
  • the type of the fault is that after the workpiece is ground, the spindle grinding wheel is not returned to the trimming, and the automatic cycle is terminated, and accordingly, the corresponding fault is searched from the running fault database;
  • the input interface of the PLC can only be repaired by replacing the input interface of the PLC, and cannot be automatically repaired by the system. Therefore, the maintenance personnel are notified to repair the fault;
  • the working state of the numerically controlled grinding machine is set by the toggle switch on the operation panel, and the toggle switch is connected to the input interface E7.0 of the PLC to check its state, no matter how the toggle switch is turned, The status is always "0", no change, and no problem is found in the check switch.
  • the intelligent monitoring method for the operating state of the machine tool provided in the embodiment can match the faults occurring in the numerical control grinding machine by running the fault database, and can determine the fault type and the repairing mode, and improve the repairing efficiency.
  • an interaction timing diagram of an intelligent monitoring method for a running state of a machine tool includes the following main bodies: a machine tool, a monitoring device, a processor, an acquiring device, and The communication device, the operation fault database and the receiving end, wherein the monitoring device, the processor, the obtaining device and the communication device are internal devices of the intelligent monitoring system of the operating state of the machine tool provided by the present invention, and the running fault database is preset storage
  • the database of the type and solution of the fault, the receiving end is a terminal device held by the maintenance personnel for Receiving the prompt repair information sent by the intelligent monitoring system provided in this embodiment, for example, it may be a terminal device having a communication transmission function such as a mobile phone, a walkie-talkie or a computer.
  • the method includes:
  • the monitoring device monitors the operating state of the machine tool.
  • the processor determines the type of operating fault.
  • the acquiring device matches the corresponding fault information from the preset running fault database according to the type of the running fault.
  • the processor determines, according to the matching result, whether the running fault can be automatically repaired by the processor.
  • the running fault is automatically repaired by the processor calling the corresponding fix.
  • the communication device sends the first repair information for notifying the maintenance personnel to manually repair the operation failure to the preset receiving end.
  • the acquiring device After the fault is repaired, the acquiring device obtains the type of the fault and the repair method.
  • the processor determines whether the repair mode can be implemented by automatic repair, and the judgment result is obtained.
  • the processor associates the type of operational failure with the outcome of the judgment and stores it in the operational fault database.
  • the acquisition device obtains the machine number, the type of the operation fault, and the time when the machine has an operation failure.
  • the processor generates a running fault record table of the machine tool and saves it.
  • the processor statistically analyzes the time, type and quantity of the machine running fault according to the running fault record table. In the preset time period, when the number of operating faults of the machine tool is greater than the preset value, the communication device sends the machine tool to the receiving end. Maintenance alarm information.
  • FIG. 8 is a structural structural diagram of an intelligent monitoring system for operating state of a machine tool according to another embodiment of the present invention, the system comprising:
  • the monitoring device 810 is configured to monitor the operating state of the machine tool.
  • the processor 820 is configured to determine the type of the operation fault when the running fault of the machine tool is monitored.
  • the obtaining device 830 is configured to match the corresponding fault information from the preset running fault database according to the type of the operating fault.
  • the processor 820 is further configured to: when the corresponding fault information is matched in the running fault database, determine, according to the matching result, whether the running fault can be automatically repaired;
  • the intelligent monitoring system of the running state of the machine tool determines the type of the fault occurring during the running of the machine tool by the processor, and matches the fault information in the preset running fault database, and whether the fault can be
  • the automatic repair judges and realizes that when the operation fault can be automatically repaired, the operation fault is automatically repaired, the work intensity of the maintenance personnel can be reduced, the repair efficiency can be improved, and the machine tool can be automatically repaired in time after the fault occurs, thereby reducing the fault. And the damage caused.
  • FIG. 9 is a structural diagram of an intelligent monitoring system for operating state of a machine tool according to another embodiment of the present invention. Based on the foregoing embodiment, a fault that cannot be automatically repaired may also be performed by the communication device 840. Sending the repair information to the maintenance personnel.
  • the intelligent monitoring system provided in this embodiment may include:
  • the monitoring device 810 is configured to monitor the operating state of the machine tool.
  • the processor 820 is configured to determine the type of the operation fault when the running fault of the machine tool is monitored.
  • the obtaining device 830 is configured to match the corresponding fault information from the preset running fault database according to the type of the operating fault.
  • the processor 820 is further configured to: when the corresponding fault information is matched in the running fault database, determine, according to the matching result, whether the running fault can be automatically repaired;
  • the communication device 840 is configured to send, to the preset receiving end, first repair information for notifying the maintenance personnel to manually repair the operation fault when the operation fault cannot be automatically repaired.
  • the intelligent monitoring system of the running state of the machine tool determines the type of the fault occurring during the running of the machine tool by the processor, and matches the fault information in the preset running fault database, and whether the fault can be
  • the automatic repair judges and realizes that when the operation fault can be automatically repaired, the operation fault is automatically repaired, the work intensity of the maintenance personnel can be reduced, the repair efficiency can be improved, and the machine tool can be automatically repaired in time after the fault occurs, thereby reducing the fault. And the damage caused.
  • processor 820 specifically includes the following units:
  • the first determining unit 8201 is connected to the monitoring device 810, and is configured to determine the type of the operating fault when the running fault of the machine tool is monitored;
  • the second determining unit 8202 is respectively connected to the obtaining device 830 and the communication device 840, and is configured to determine whether the running fault can be automatically repaired according to the matching result when the corresponding fault information is matched in the running fault database;
  • the calling unit 8203 is configured to automatically repair the running fault by calling the corresponding repairing program when the running fault can be automatically repaired;
  • the third determining unit 8204 is connected to the communication device 840, and is configured to determine whether the repair mode not included in the operation error database can be implemented by automatic repair, and obtain a determination result;
  • the association unit 8205 is configured to associate the type of the operation fault with the determination result, and store the result in the operation failure database;
  • the generating unit 8206 is configured to generate and save the running fault record table of the machine tool according to the number of the machine tool, the type of the running fault, and the time when the machine tool has an operating fault;
  • the processing unit 8207 is configured to: time, type and quantity of operation failures of the machine tool according to the operation fault record table conduct statistical analysis;
  • the fourth determining unit 8208 is connected to the communication device 840 and configured to determine whether the number of operating faults of the machine tool is greater than a preset value within a preset time period.
  • the processor of the intelligent monitoring system of the running state of the machine tool determines the type of the fault occurring during the running of the machine tool by the processor, and matches the fault information in the preset running fault database, and Whether the fault can be automatically repaired and judged, and when the operation fault can be automatically repaired, the fault of the operation is automatically repaired, the work intensity of the maintenance personnel can be reduced, the repair efficiency can be improved, and the machine tool can be automatically repaired in time after the fault occurs. Reduce losses caused by malfunctions.
  • FIG. 11 is a connection diagram of an intelligent monitoring system for operating state of a machine tool according to another embodiment of the present invention. The connection relationship between the intelligent control system and the system is described below in conjunction with the figure.
  • the intelligent control system 1110 is connected to the plurality of machine tools 1120, and monitors the operating condition of the machine tool 1120. When any of the plurality of machine tools 1120 has an operational failure, the fault information is matched from the operation fault database 1130, and according to The matching result sends the fault repair information to the receiving end 1140.
  • the intelligent monitoring system for the running state of the machine tool provided by the embodiment provides a timely notification by monitoring a plurality of machine tools, matching the fault information from the running fault database, and transmitting the fault repairing information to the receiving end according to the matching result. Maintenance personnel repair the failed machine tool and improve the efficiency of maintenance.
  • a network topology diagram of an intelligent monitoring system for operating state of a machine tool is provided.
  • the monitoring device 810 for monitoring each machine tool 1120 is in a star network topology, and the monitoring device 810 is installed in On the machine tool 1120, the 433Mhz industrial free frequency band is wirelessly connected to the processor 820, and the processor 820 is connected to a plurality of aggregation nodes 850.
  • the aggregation nodes transmit information to the processor 820.
  • the processor 820 processes the information. Then, it is sent to the receiving end 1140 through the communication device 840.
  • the receiving end 1140 may be a terminal device having a network communication function, such as a mobile phone or a computer.
  • the processor 820 transmits the information to the database of the backend server 860 through the communication device 840, and the communication device 840 accesses the Internet of Things through the gateway 870, and then communicates with the server 860.
  • the communication device 840 Before transmitting the data to the database of the server 860, the communication device 840 needs to be registered first through the gateway 870. After the registration is successful, the gateway 870 sends the authentication information corresponding to the communication device to the server 860 for authentication. After the authentication is successful, the communication device 840 and the server 860 establish a connection through the Internet of Things, and then the information can be transmitted through the communication device 840 and the server 860.
  • the disclosed apparatus and method may be implemented in other manners.
  • the device embodiments described above are merely illustrative.
  • the division of cells is only a logical function division.
  • multiple units or components may be combined or integrated. Go to another system, or some features can be ignored or not executed.
  • the units described as separate components may or may not be physically separate, and the components displayed as units may or may not be physical units, that is, may be located in one place, or may be distributed to multiple network units. Some or all of the units may be selected according to actual needs to achieve the objectives of the embodiments of the present invention.
  • each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit.
  • the above integrated unit can be implemented in the form of hardware or in the form of a software functional unit.
  • An integrated unit if implemented in the form of a software functional unit and sold or used as a standalone product, can be stored in a computer readable storage medium.
  • the technical solution of the present invention contributes in essence or to the prior art, or all or part of the technical solution may be embodied in the form of a software product stored in a storage medium.
  • a number of instructions are included to cause a computer device (which may be a personal computer, server, or network device, etc.) to perform all or part of the steps of the various embodiments of the present invention.
  • the foregoing storage medium includes: a U disk, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM, Random Access Memory), a magnetic disk, or an optical disk, and the like, which can store program codes.

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  • Numerical Control (AREA)

Abstract

一种机床运行状态的智能监控方法及系统，该方法包括以下步骤：对机床的运行状态进行监控，当监控到机床出现运行故障时，判断该运行故障的类型（101）；根据该运行故障的类型从预设的运行故障数据库中匹配相应的故障信息（102）；当在运行故障数据库中匹配到相应的故障信息时，根据匹配结果，判断该运行故障是否能自动修复（103）；当运行故障能自动修复时，对运行故障进行自动修复（104）。该机床运行状态的智能监控方法及系统，实现了当运行故障能被自动修复时，自动对运行故障进行修复，能够减少维修人员的工作强度，提高修复效率，使机床在出现故障后，及时地自动修复，减少因故障而造成的损失。

Description

一种机床运行状态的智能监控方法及系统 技术领域
本发明涉及工业智能监控领域，尤其涉及一种机床运行状态的智能监控方法及智能监控系统。
背景技术
在数控系统加工中，需要对机床的工作状态进行监控，以便在机床工作过程中出现问题时及时发现并解决。
对于机床工作状态的监控通常采用数控传感器网络系统，而现有的数控机床系统中，通常只是通过有线或无线的连接方式将传感器与处理器连接起来，对机床的工作状态进行监控，当机床出行运行故障时，通过声光报警灯方式提醒工作人员。这种方式无法对机床的故障进行有效的分析，无法知道具体哪台机床容易出现什么样的问题，智能凭借经验判断或人工记录各机床出现的故障，当机床数量多时，通过人工记录的方法就有很大的局限和不便利。
同时，对于部分简单的故障，只需要通过修改参数或重启机床等就可以解决，如果对于所有的故障都通知工作人员，无疑会加大工作人员的工作强度，且当机床数量多时，工作人员的维修维护效率也会变低，因此，亟需一种可以自动判断运行故障并自动修复故障的方案。
发明内容
本发明所要解决的技术问题是针对现有技术在监控机床运行情况方面的不足，提供了一种用于监控机床运行状态的智能监控方法及智能监控系统。
本发明解决上述技术问题的技术方案如下：
一种机床运行状态的智能监控方法，包括以下步骤：
步骤1，对机床的运行状态进行监控，当监控到所述机床出现运行故障时，判断所述运行故障的类型；
步骤2，根据所述运行故障的类型从预设的运行故障数据库中匹配相应的故障信息；
步骤3，当在所述运行故障数据库中匹配到相应的故障信息时，判断所述运行故障是否能自动修复；
步骤4，当所述运行故障能自动修复时，对所述运行故障进行自动修复。
本发明的有益效果是：本发明提供的一种机床运行状态的智能监控方法，通过对机床运行过程中出现的故障类型进行判断，并与预设的运行故障数据库中的故障信息进行 匹配，并对故障是否能够自动修复进行判断，实现了当运行故障能被自动修复时，自动对运行故障进行修复，能够减少维修人员的工作强度，提高修复效率，使机床在出现故障后，及时地自动修复，减少因故障而造成的损失。
在上述技术方案的基础上，本发明还可以做如下改进。
进一步地，所述智能监控方法还包括以下步骤：
获取修复程序；
将所述修复程序与所述修复程序能够修复的所述运行故障进行关联；
建立自动修复程序库，所述自动修复程序库包含多种用于修复所述运行故障的修复程序。
上述进一步方案中，通过建立自动修复程序库，当机床的运行过程中出现运行故障时，可以迅速的从自动修复程序库中调用相应的修复程序，能够及时地自动修复运行故障，减少因故障而造成的损失。
进一步地，步骤4中，对所述运行故障进行自动修复具体为：
通过调用所述自动修复程序库中的所述修复程序，对所述运行故障进行修复。
上述进一步方案中，通过从自动修复程序库中调用相应的修复程序，能够及时地自动修复运行故障，减少因故障而造成的损失。
本发明解决上述技术问题的另一种技术方案如下：
一种机床运行状态的智能监控系统，包括：
监控装置，用于对机床的运行状态进行监控；
处理器，用于当所述机床出现运行故障时，判断所述运行故障的类型；
通信装置，用于根据所述运行故障的类型从预设的运行故障数据库中匹配相应的故障信息；
所述处理器还用于当在所述运行故障数据库中匹配到相应的故障信息时，判断所述运行故障是否能自动修复；
并当所述运行故障能自动修复时，对所述运行故障进行自动修复。
本发明提供的一种机床运行状态的智能监控系统，通过处理器对机床运行过程中出现的故障类型进行判断，并与预设的运行故障数据库中的故障信息进行匹配，并对故障是否能够自动修复进行判断，实现了当运行故障能被自动修复时，自动对运行故障进行修复，能够减少维修人员的工作强度，提高修复效率，使机床在出现故障后，及时地自动修复，减少因故障而造成的损失。
在上述技术方案的基础上，本发明还可以做如下改进。
进一步地，所述智能监控系统还包括：
修复程序获取装置，用于获取修复程序；
修复程序关联装置，用于将所述修复程序与所述修复程序能够修复的所述运行故障进行关联；
自动修复程序库，用于存储多种用于修复所述运行故障的修复程序。
上述进一步方案中，自动修复程序中存储有修复程序，当机床的运行过程中出现运行故障时，通过调用相应地修复程序，能够及时地自动修复运行故障，减少因故障而造成的损失。
进一步地，所述处理器对所述运行故障进行自动修复的过程具体为：
通过调用所述自动修复程序库中的所述修复程序，对所述运行故障进行修复。
上述进一步方案中，处理器通过从自动修复程序库中调用相应的修复程序，能够及时地自动修复运行故障，减少因故障而造成的损失。
本发明附加的方面的优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本发明实践了解到。
附图说明
图1为本发明实施例提供的一种机床运行状态的智能监控方法的流程示意图；
图2为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图；
图3为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图；
图4为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图；
图5为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图；
图6为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图；
图7为本发明另一实施例提供的一种机床运行状态的智能监控方法的交互时序图；
图8为本发明另一实施例提供的一种机床运行状态的智能监控系统的结构框架图；
图9为本发明另一实施例提供的一种机床运行状态的智能监控系统的结构图；
图10为本发明另一实施例提供的一种机床运行状态的智能监控系统的结构图；
图11为本发明另一实施例提供的一种机床运行状态的智能监控系统的连接关系图；
图12为本发明另一实施例提供的一种机床运行状态的智能监控系统的网络拓扑图。
具体实施方式
以下描述中，为了说明而不是为了限定，提出了诸如特定系统结构、接口、技术之类的具体细节，以便透切理解本发明。然而，本领域的技术人员应当清楚，在没有这些具体细节的其它实施例中也可以实现本发明。在其它情况中，省略对众所周知的系统、电路以及方法的详细说明，以免不必要的细节妨碍本发明的描述。
如图1所示，为本发明实施例提供的一种机床运行状态的智能监控方法的流程示意图，该方法包括以下步骤：
S101，对机床的运行状态进行监控，当监控到机床出现运行故障时，判断该运行故障的类型；
S102，根据该运行故障的类型从预设的运行故障数据库中匹配相应的故障信息；
S103，当在运行故障数据库中匹配到相应的故障信息时，根据匹配结果，判断该运行故障是否能自动修复；
S104，当运行故障能自动修复时，对运行故障进行自动修复。
本实施例中提供的一种机床运行状态的智能监控方法，通过对机床运行过程中出现的故障类型进行判断，并与预设的运行故障数据库中的故障信息进行匹配，并对故障是否能够自动修复进行判断，实现了当运行故障能被自动修复时，自动对运行故障进行修复，能够减少维修人员的工作强度，提高修复效率，使机床在出现故障后，及时地自动修复，减少因故障而造成的损失。
在上述实施例的基础上，本发明另一实施例提供了一种机床运行状态的智能监控方法，还可以包括以下步骤：
获取修复程序，这里的修复程序是针对软件运行错误进行自动修复的软件或程序，也可以针对部分硬件错误进行修复，例如，当机床的运行参数出错时，可以根据预设的参数对错误进行修复，又例如，当机床出现死机的情况时，可以通过重启机床来实现修复，那么修复程序就可以设置为重启机床，其实现方式可以通过软件控制实现，也可以通过控制机械实现；
将修复程序与修复程序能够修复的运行故障进行关联，这里指的是一个映射的过程，就是将修复程序和对应的故障类型进行关联，当匹配到相应的故障类型时，就可以调用该修复程序对故障进行自动修复，或者，某一修复程序对应修复多种故障，当出现任一故障时，可以调用修复程序中相关的内容，对故障进行修复，这也是一种关联；
建立自动修复程序库，自动修复程序库包含多种用于修复运行故障的修复程序，这里的自动修复程序库中存储的修复程序可以是一种修复程序对应一种运行故障，也可以是一种修复程序对应了多种故障。
通过建立自动修复程序库，当机床的运行过程中出现运行故障时，可以迅速的从自动修复程序库中调用相应的修复程序，能够及时地自动修复运行故障，减少因故障而造成的损失。
在此基础上，步骤S104中，对运行故障进行自动修复具体可以为：
通过调用自动修复程序库中的修复程序，对运行故障进行修复，例如，当出现某一故障时，分析故障得到故障的类型后，将故障的类型与自动修复程序库中的修复程序进行匹配，就可以自动调用修复程序对机床的运行故障进行修复。
本实施例中提供的一种机床运行状态的智能监控方法，通过从自动修复程序库中调用相应的修复程序，能够及时地自动修复运行故障，减少因故障而造成的损失。
如图2所示，为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图，在基于上述实施例的基础上，还可以对不能自动修复的故障进行处理，具体包括以下步骤：
S201，对机床的运行状态进行监控，当监控到机床出现运行故障时，判断运行故障的类型，这里的机床可以理解为通常意义上的数控机床，对其运行状态进行监控，指的是对其正常工作状态进行监控，当其工作状态与正常的工作状态不同时，判断该机床出现了运行故障，根据其运行故障的表现形式，可以判断得到该机床的故障的类型；
需要说明的是，这对机床的运行状态进行监控，可以分为软件监控和硬件监控，其中，软件监控通过对机床的设定参数或控制系统等进行监控，检测机床的工作状态；
而硬件监控则通过对机床的温度、电流或振动等物理量来检测机床的工作状态，例如，可以通过温度传感器、视频监控器、图像处理器等实现监控；
例如，可以通过预先编写好的检测程序对运行故障进行检测，当发现运行故障时，通过分析程序自动采集并分析运行故障的特征，根据运行故障的特征判断运行故障的类型，例如，当机床出现死机的情况时，其特征就是各软件和机床无反应，因此可以确定其故障是死机，在此基础上，可以对各故障的特征进行分类识别；
又例如，当检测到机床出现异常振动时，可以根据预先编写好的检测程序判断机床的故障类型；
其中，运行故障包括机械故障、电气故障、系统故障等无法使机床继续正常工作的故障；
S202，根据运行故障的类型从预设的运行故障数据库中匹配相应的故障信息，例如，当检测到机床振动过于剧烈，超过阈值时，从运行故障数据库中匹配与机床振动剧烈这一运行故障相对应的故障类型；
S203，当在运行故障数据库中匹配到相应的故障信息时，根据匹配结果，判断运行故障是否能自动修复，当运行故障能自动修复时，执行S204，当运行故障不能自动修复时，执行S205，例如，运行故障数据库中存储有机床振动剧烈这一故障类型，那么当检测到机床振动过于剧烈时，就可以从运行故障数据库中匹配到相应的故障信息，再根据运行故障数据库中存储的对于机床振动剧烈这一故障类型是否可以自动修复的信息，判断机床振动剧烈这一故障类型是否可以自动修复；
S204，对运行故障进行自动修复，例如，当机床出现由于瞬时故障引起的系统报警时，可用硬件复位或开关系统电源依次来清除故障，经过判断，发现这一故障类型可以通过开关系统电源这一操作来自动修复，那么系统调用预存的程序，对出现故障的机床进行开关系统电源这一操作，对运行故障进行自动修复；
S205，向预设的接收端发送用于通知维修人员对运行故障进行手动修复的第一报修信息，例如，当通过对机床的电路板进行检测，发现机床的某一电路板损坏时，将电路板损坏这一故障类型与运行故障数据库中的故障信息进行匹配，发现这一运行故障不能通过自动修复进行修复，需要人工用新的电路板替换损坏的电路板，因此，向维修人员发送对电路板损坏这一故障进行人工修复的通知。
本实施例中提供的一种机床运行状态的智能监控方法，通过将出现运行故障的类型与预设的运行故障数据库中的故障信息进行匹配，判断故障是否能够自动修复，可以自 动修复简单的故障，减少了维修人员的工作量，并且在只有不能自动修复运行故障时，才通知维修人员，提高修复效率。
如图3所示，为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图，在基于上述实施例的基础上，还可以对未匹配到相应的故障类型的故障进行处理，具体包括以下步骤：
S301，对机床的运行状态进行监控，当监控到机床出现运行故障时，判断运行故障的类型；
S302，根据运行故障的类型从预设的运行故障数据库中匹配相应的故障信息，判断是否能在运行故障数据库中匹配到相应的故障信息，当在运行故障数据库中未匹配到相应的故障信息时，执行S303，当在运行故障数据库中匹配到相应的故障信息时，执行S304；
S303，向接收端发送用于通知维修人员对运行故障进行手动修复并检查运行故障的类型的第二报修信息，该运行故障指的是运行故障数据库中未存储的新的运行故障，或未能识别其类型的运行故障，当在运行故障数据库中未匹配到相应的故障类型时，无法得知该运行故障是否能自动修复，向维修人员发送对该运行故障进行人工排查修复的修复信息；
S304，根据匹配结果，判断运行故障是否能自动修复，当运行故障能自动修复时，执行S305，当运行故障不能自动修复时，执行S306；
S305，对运行故障进行自动修复；
S306，向预设的接收端发送用于通知维修人员对运行故障进行手动修复的第一报修信息；
S307，当运行故障修复后，获取运行故障的类型和修复方式，例如，当故障为电路板烧毁时，对其修复方式是更换新的电路板，修复方式是更换新的电路板，又例如，当故障为用户的程序错误造成机床故障停机时，维修人员对其进行排查后发现通过机床系统自带的块搜索功能就能进行检查，修复所有错误，因此，故障类型是用户程序错误，对其修复方式是调用机床系统自带的块搜索功能对故障进行检查并修复；
S308，判断修复方式是否能通过自动修复实现，得到判断结果，例如，在上一步骤的例子中，当故障为电路板烧毁时，对其修复方式是更换新的电路板，通过判断发现这种修复方式不能通过系统自动修复实现，需要维修人员手动修复，当故障为用户的程序错误造成机床故障停机时，维修人员对其进行排查后发现通过机床系统自带的块搜索功能就能进行检查，修复所有错误，因此，通过通过判断发现这种修复方式能通过系统自动修复实现；
S309，将运行故障的类型和判断结果进行关联，并存储在运行故障数据库中，例如，在上一步骤的例子中，当故障为电路板烧毁时，就将这一故障类型和对应的修复方式(更换新的电路板)进行关联，存储在运行故障数据库中，当故障为用户的程序错误造成机 床故障停机时，将这一故障和对应的修复方式(调用机床系统自带的块搜索功能对故障进行检查并修复故障)进行关联，并将对应的自动修复过程存储在运行故障数据库中。
本实施例中提供的一种机床运行状态的智能监控方法，通过在对未知的运行错误进行修复后，判断其类型和修复方式，并存储在运行故障数据库中，以便下次出现相同的错误时，能够对该类型的错误进行识别和处理，提高了处理故障的效率。
如图4所示，为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图，在基于上述实施例的基础上，还可以对运行故障的信息进行收集和存储，具体包括以下步骤：
S401，对机床的运行状态进行监控，当监控到机床出现运行故障时，判断运行故障的类型；
S402，根据运行故障的类型从预设的运行故障数据库中匹配相应的故障信息，判断是否能在运行故障数据库中匹配到相应的故障信息，当在运行故障数据库中未匹配到相应的故障信息时，执行S403，当在运行故障数据库中匹配到相应的故障信息时，执行S404；
S403，向接收端发送用于通知维修人员对运行故障进行手动修复并检查运行故障的类型的第二报修信息；
S404，根据匹配结果，判断运行故障是否能自动修复，当运行故障能自动修复时，执行S405，当运行故障不能自动修复时，执行S406；
S405，对运行故障进行自动修复；
S406，向预设的接收端发送用于通知维修人员对运行故障进行手动修复的第一报修信息；
S407，当运行故障修复后，获取运行故障的类型和修复方式；
S408，判断修复方式是否能通过自动修复实现，得到判断结果；
S409，将运行故障的类型和判断结果进行关联，并存储在运行故障数据库中；
S410，获取机床的编号、运行故障的类型和机床出现运行故障的时间，生成机床的运行故障记录表并保存，例如，当机床出现工作温度过高时，通过本实施例中上述各过程判断发现不可自动修复，在通过维修人员进行排查修复后，发现使风扇被堵，通过疏通风扇解决了该问题，那么在修复完成后，自动获取出现故障的机床的编号，以及发现该机床温度过高的时间，以及造成该机床温度过高的原因，以及解决办法，将出现故障的机床的编号、发现该机床温度过高的时间、造成该机床温度过高的原因和机床过热故障存储在一张数据表中，又例如，可以每个机床都有一张专属的记录表，专门记录该机床出现的故障，或者，根据故障的类型建立记录表，分别将出现该故障的时间和机床编号及记录在其中，或者，可以将各机床出现的错误统计在同一张记录表中，便于查看。
本实施例中提供的一种机床运行状态的智能监控方法，通过对机床运行过程中出现的故障进行修复，并在该故障修复后，将该故障的类型、机床的编号及修复的时间进行 存储，便于对故障原因和易出故障的机床进行分析。
如图5所示，为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图，该智能监控方法还可以包括以下步骤：
S501，对机床的运行状态进行监控，当监控到机床出现运行故障时，判断运行故障的类型；
S502，根据运行故障的类型从预设的运行故障数据库中匹配相应的故障信息，判断是否能在运行故障数据库中匹配到相应的故障信息，当在运行故障数据库中未匹配到相应的故障信息时，执行S503，当在运行故障数据库中匹配到相应的故障信息时，执行S504；
S503，向接收端发送用于通知维修人员对运行故障进行手动修复并检查运行故障的类型的第二报修信息；
S504，根据匹配结果，判断运行故障是否能自动修复，当运行故障能自动修复时，执行S505，当运行故障不能自动修复时，执行S506；
S505，对运行故障进行自动修复；
S506，向预设的接收端发送用于通知维修人员对运行故障进行手动修复的第一报修信息；
S507，当运行故障修复后，获取运行故障的类型和修复方式；
S508，判断修复方式是否能通过自动修复实现，得到判断结果；
S509，将运行故障的类型和判断结果进行关联，并存储在运行故障数据库中；
S510，获取机床的编号、运行故障的类型和机床出现运行故障的时间，生成机床的运行故障记录表并保存；
S511，根据运行故障记录表对机床出现运行故障的时间、类型和数量进行统计分析，在预设时间段内，当机床的运行故障的数量大于预设值时，向接收端发送机床需要维护的报警信息，例如，以某机床A和机床B为例，建立机床A和机床B的运行故障记录表，分别对机床A和机床B在第一季度1至3月中的出现运行故障的时间、类型和数量进行进行收集，发现在第一季度中，机床A只出现过一次故障，是随机故障，随机故障指的是在同样条件下，只偶尔出现一次或者二次的故障，例如磨沟槽的位置发生变化等，而机床B出现过多次故障，例如，机床B是一台使用FANUC 0iTC系统的数控车床，该车床出现10次417报警，对应的修复方式是修改参数NO:2023，因此，可以将运行故障数量的预设值设置为5次，分别对机床A和机床B进行判断，发现机床A的故障次数小于5次，而机床B出现417报警的次数大于5次，因此，将机床B易出现417报警的信息发送给维修人员，由维修人员对机床B进行维护。
优选地，还可以根据运行故障记录表，对每个机床建立运行故障模型，分析每个机床出现过的故障的类型、数量和频率，对每个机床进行评分，便于精确掌握和评价机床的运行状态和机床的工作质量。
本实施例中提供的一种机床运行状态的智能监控方法，通过对机床运行过程中出现的故障类型进行判断，并与预设的运行故障数据库中的故障信息进行匹配，并对故障是否能够自动修复进行判断，实现了当运行故障能被自动修复时，自动对运行故障进行修复，能够减少维修人员的工作强度，提高修复效率，使机床在出现故障后，及时地自动修复，减少因故障而造成的损失。
如图6所示，为本发明另一实施例提供的一种机床运行状态的智能监控方法的流程图，在基于上述实施例的基础上，通过具体的实例，来说明当检测到运行故障时，该智能监控方法的流程，以德国SIEMENS810系统的数控磨床制作螺母为例，该智能监控方法包括以下步骤：
S601，在接收到制作螺母的任务后，数控磨床开始工作，按照输入的程序对螺母进行打磨，当数控磨床开始启动后，就对制作过程进行监控，在制作过程中，发现某数控磨床的自动加工不能连续进行，磨削完一个螺母后，主轴砂轮不退回修整，自动循环终止；
S602，得到故障的类型是磨削完一个工件后，主轴砂轮不退回修整，自动循环终止，据此从运行故障数据库中查找对应的故障；
S603，在运行故障数据库中匹配到了相应的故障，该数控磨床出现过相同的问题，发现是PLC的输入接口损坏导致的；
S604，PLC的输入接口损坏只能通过更换PLC的输入接口来修复该故障，不可被系统自动修复，因此，通知维修人员对该故障进行修复；
需要说明的是，该数控磨床的工作状态是通过操作面板上的钮子开关设定的，钮子开关接入PLC的输入接口E7.0，检查其状态，不管怎样拨动钮子开关，其状态一直为“0”，不发生变化，而检查开关没有发现问题，将该开关的连接线连接到PLC的备用输入接口E3.0上，这时观察这个状态的变化，正常跟随钮子开关的变化，没有问题，由此证明PLC的输入接口E7.0损坏，由此确定故障实际为PLC的输入接口损坏，其修复方式为更换PLC的输入接口E7.0；
S605，在修复完后，将该故障的类型、该故障的出现时间以及维修记录存储在该数控磨床的运行故障记录表中。
本实施例中提供的一种机床运行状态的智能监控方法，通过运行故障数据库对该数控磨床出现的故障进行匹配，能够判断其出现故障类型和修复方式，提高了修复的效率。
如图7所示，为本发明另一实施例提供的一种机床运行状态的智能监控方法的交互时序图，共包括以下几个主体，分别为：机床、监控装置、处理器、获取装置、通信装置、运行故障数据库和接收端，其中，监控装置、处理器、获取装置和通信装置是本发明提供的一种机床运行状态的智能监控系统的内部装置，运行故障数据库是预设的存储有运行故障的类型和解决方案的数据库，接收端是维修人员持有的一种终端设备，用于 接收本实施例提供的智能监控系统发出的提示报修信息，例如，可以是手机、对讲机或电脑等具有通信传输功能的终端设备。
下面结合图7对本实施例提供的监控方法进行详细说明。
该方法包括：
监控装置对机床的运行状态进行监控，当监控到机床出现运行故障时，由处理器判断运行故障的类型。
获取装置根据运行故障的类型从预设的运行故障数据库中匹配相应的故障信息。
当获取装置在运行故障数据库中匹配到相应的故障信息时，处理器根据匹配结果，通过处理器判断运行故障是否能自动修复。
当运行故障能自动修复时，通过处理器调用相应的修复程序对运行故障进行自动修复。
当运行故障不能自动修复时，通信装置向预设的接收端发送用于通知维修人员对运行故障进行手动修复的第一报修信息。
当运行故障修复后，获取装置获取运行故障的类型和修复方式。
处理器判断修复方式是否能通过自动修复实现，得到判断结果。
处理器将运行故障的类型和判断结果进行关联，并存储在运行故障数据库中。
获取装置获取机床的编号、运行故障的类型和机床出现运行故障的时间，处理器生成机床的运行故障记录表并保存。
处理器根据运行故障记录表对机床出现运行故障的时间、类型和数量进行统计分析，在预设时间段内，当机床的运行故障的数量大于预设值时，通信装置向接收端发送机床需要维护的报警信息。
如图8所示，为本发明另一实施例提供的一种机床运行状态的智能监控系统的结构框架图，该系统包括：
监控装置810，用于对机床的运行状态进行监控。
处理器820，用于当监控到机床出现运行故障时，判断运行故障的类型。
获取装置830，用于根据运行故障的类型从预设的运行故障数据库中匹配相应的故障信息。
处理器820还用于当在运行故障数据库中匹配到相应的故障信息时，根据匹配结果，判断运行故障是否能自动修复；
并当运行故障能自动修复时，对运行故障进行自动修复。
本实施例提供的一种机床运行状态的智能监控系统，通过处理器对机床运行过程中出现的故障类型进行判断，并与预设的运行故障数据库中的故障信息进行匹配，并对故障是否能够自动修复进行判断，实现了当运行故障能被自动修复时，自动对运行故障进行修复，能够减少维修人员的工作强度，提高修复效率，使机床在出现故障后，及时地自动修复，减少因故障而造成的损失。
如图9所示，为本发明另一实施例提供的一种机床运行状态的智能监控系统的结构图，在基于上述实施例的基础上，针对不能自动修复的故障，还可以通过通信装置840向维修人员发送报修信息，具体地，本实施例提供智能监控系统可以包括：
监控装置810，用于对机床的运行状态进行监控。
处理器820，用于当监控到机床出现运行故障时，判断运行故障的类型。
获取装置830，用于根据运行故障的类型从预设的运行故障数据库中匹配相应的故障信息。
处理器820还用于当在运行故障数据库中匹配到相应的故障信息时，根据匹配结果，判断运行故障是否能自动修复；
并当运行故障能自动修复时，对运行故障进行自动修复。
通信装置840，用于当运行故障不能自动修复时，向预设的接收端发送用于通知维修人员对运行故障进行手动修复的第一报修信息。
本实施例提供的一种机床运行状态的智能监控系统，通过处理器对机床运行过程中出现的故障类型进行判断，并与预设的运行故障数据库中的故障信息进行匹配，并对故障是否能够自动修复进行判断，实现了当运行故障能被自动修复时，自动对运行故障进行修复，能够减少维修人员的工作强度，提高修复效率，使机床在出现故障后，及时地自动修复，减少因故障而造成的损失。
由上述系统实施例可知，处理器在该监控系统中起到了重要的作用，因此，本实施例中将对处理器进行进一步地说明。
如图10所示，为本发明另一实施例提供的一种机床运行状态的智能监控系统的处理器结构图，处理器820具体包括以下单元：
第一判断单元8201，与监控装置810连接，用于当监控到机床出现运行故障时，判断运行故障的类型；
第二判断单元8202，分别与获取装置830和通信装置840连接，用于当在运行故障数据库中匹配到相应的故障信息时，根据匹配结果，判断运行故障是否能自动修复；
调用单元8203，用于当运行故障能自动修复时，调用相应地修复程序对运行故障进行自动修复；
第三判断单元8204，与通信装置840连接，用于判断运行错误数据库中未包含的修复方式是否能通过自动修复实现，得到判断结果；
关联单元8205，用于将运行故障的类型和判断结果进行关联，并存储在运行故障数据库中；
生成单元8206，用于根据机床的编号、运行故障的类型和机床出现运行故障的时间，生成机床的运行故障记录表并保存；
处理单元8207，用于根据运行故障记录表对机床出现运行故障的时间、类型和数量 进行统计分析；
第四判断单元8208，与通信装置840连接，用于判断在预设时间段内，机床的运行故障的数量是否大于预设值。
本实施例提供的一种机床运行状态的智能监控系统的处理器，通过处理器对机床运行过程中出现的故障类型进行判断，并与预设的运行故障数据库中的故障信息进行匹配，并对故障是否能够自动修复进行判断，实现了当运行故障能被自动修复时，自动对运行故障进行修复，能够减少维修人员的工作强度，提高修复效率，使机床在出现故障后，及时地自动修复，减少因故障而造成的损失。
如图11所示，为本发明另一实施例提供的一种机床运行状态的智能监控系统的连接关系图，下面结合该图，对该智能控制系统与与他系统的连接关系进行说明。
该智能控制系统1110与多个机床1120连接，并对机床1120的运行状况进行监控，当多个机床1120中有任意机床1120发生运行故障时，从运行故障数据库1130中匹配故障的信息，并根据匹配结果向接收端1140发送故障报修信息。
本实施例提供的一种机床运行状态的智能监控系统，通过对多个机床进行监控，并从运行故障数据库中匹配故障的信息，并根据匹配结果向接收端发送故障报修信息，能够及时地通知维修人员对出故障的机床进行维修，提高了维修的效率。
如图12所示，为本发明另一实施例提供的一种机床运行状态的智能监控系统的网络拓扑图，对各机床1120进行监控的监控装置810呈星装网络拓扑，监控装置810安装在机床1120上，通过433Mhz工业免费频段与处理器820无线连接，处理器820连接有多个汇聚节点850，这些汇聚节点将信息传输到处理器820中，一方面，处理器820在对信息进行处理后通过通信装置840发送给接收端1140，其中，接收端1140可以是手机、电脑等具有网络通信功能的终端设备。
另一方面，处理器820在对信息进行处理后通过通信装置840发送给后端服务器860的数据库中，通信装置840通过网关870接入物联网，再与服务器860实现通信。
在将数据传输到服务器860的数据库中之前，首先需要通过网关870对通信装置840进行注册，在注册成功之后，网关870会将与通信装置对应的鉴权信息发送到服务器860中进行鉴权，在鉴权成功后，通信装置840与服务器860通过物联网建立了连接，然后就可以通过通信装置840与服务器860传输信息了。
读者应理解，在本说明书的描述中，参考术语“一个实施例”、“一些实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不必针对的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特点可以在任一个或多个实施例或示例中以合适的方式结合。此外，在 不相互矛盾的情况下，本领域的技术人员可以将本说明书中描述的不同实施例或示例以及不同实施例或示例的特征进行结合和组合。
所属领域的技术人员可以清楚地了解到，为了描述的方便和简洁，上述描述的装置和单元的具体工作过程，可以参考前述方法实施例中的对应过程，在此不再赘述。
在本申请所提供的几个实施例中，应该理解到，所揭露的装置和方法，可以通过其它的方式实现。例如，以上所描述的装置实施例仅仅是示意性的，例如，单元的划分，仅仅为一种逻辑功能划分，实际实现时可以有另外的划分方式，例如多个单元或组件可以结合或者可以集成到另一个系统，或一些特征可以忽略，或不执行。
作为分离部件说明的单元可以是或者也可以不是物理上分开的，作为单元显示的部件可以是或者也可以不是物理单元，即可以位于一个地方，或者也可以分布到多个网络单元上。可以根据实际的需要选择其中的部分或者全部单元来实现本发明实施例方案的目的。
另外，在本发明各个实施例中的各功能单元可以集成在一个处理单元中，也可以是各个单元单独物理存在，也可以是两个或两个以上单元集成在一个单元中。上述集成的单元既可以采用硬件的形式实现，也可以采用软件功能单元的形式实现。
集成的单元如果以软件功能单元的形式实现并作为独立的产品销售或使用时，可以存储在一个计算机可读取存储介质中。基于这样的理解，本发明的技术方案本质上或者说对现有技术做出贡献的部分，或者该技术方案的全部或部分可以以软件产品的形式体现出来，该计算机软件产品存储在一个存储介质中，包括若干指令用以使得一台计算机设备(可以是个人计算机，服务器，或者网络设备等)执行本发明各个实施例方法的全部或部分步骤。而前述的存储介质包括：U盘、移动硬盘、只读存储器(ROM，Read-OnlyMemory)、随机存取存储器(RAM，RandomAccessMemory)、磁碟或者光盘等各种可以存储程序代码的介质。
以上，仅为本发明的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到各种等效的修改或替换，这些修改或替换都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应以权利要求的保护范围为准。

Claims (10)

  1. 一种机床运行状态的智能监控方法，其特征在于，包括以下步骤：
    步骤1，对机床的运行状态进行监控，当监控到所述机床出现运行故障时，判断所述运行故障的类型；
    步骤2，根据所述运行故障的类型从预设的运行故障数据库中匹配相应的故障信息；
    步骤3，当在所述运行故障数据库中匹配到相应的故障信息时，判断所述运行故障是否能自动修复；
    步骤4，当所述运行故障能自动修复时，对所述运行故障进行自动修复。
  2. 根据权利要求1所述的智能监控方法，其特征在于，还包括：
    步骤5，当所述运行故障不能自动修复时，向预设的接收端发送用于通知维修人员对所述运行故障进行手动修复的第一报修信息。
  3. 根据权利要求2所述的智能监控方法，其特征在于，还包括：
    步骤6，当在所述运行故障数据库中未匹配到相应的故障信息时，向所述接收端发送用于通知维修人员对所述运行故障进行手动修复并检查所述运行故障的类型的第二报修信息；
    步骤7，当所述运行故障修复后，获取所述运行故障的类型和修复方式；
    步骤8，判断所述修复方式是否能通过自动修复实现，得到判断结果；
    步骤9，将所述运行故障的类型和所述判断结果进行关联，并存储在所述运行故障数据库中。
  4. 根据权利要求2或3所述的智能监控方法，其特征在于，还包括：
    步骤10，获取所述机床的编号、所述运行故障的类型和所述机床出现运行故障的时间，生成所述机床的运行故障记录表并保存。
  5. 根据权利要求4所述的智能监控方法，其特征在于，还包括：
    步骤11，根据所述运行故障记录表对所述机床出现运行故障的时间、类型和数量进行统计分析，在预设时间段内，当所述机床的运行故障的数量大于预设值时，向所述接收端发送所述机床需要维护的报警信息。
  6. 一种机床运行状态的智能监控系统，其特征在于，包括：
    监控装置，用于对机床的运行状态进行监控；
    处理器，用于当监控到所述机床出现运行故障时，判断所述运行故障的类型；
    获取装置，用于根据所述运行故障的类型从预设的运行故障数据库中匹配相应的故障信息；
    所述处理器还用于当在所述运行故障数据库中匹配到相应的故障信息时，判断所述运行故障是否能自动修复；
    并当所述运行故障能自动修复时，对所述运行故障进行自动修复。
  7. 根据权利要求6所述的智能监控系统，其特征在于，还包括：
    通信装置，用于当所述运行故障不能自动修复时，向预设的接收端发送用于通知维修人员对所述运行故障进行手动修复的第一报修信息。
  8. 根据权利要求7所述的智能监控系统，其特征在于，所述通信装置还用于当在所述运行故障数据库中未匹配到相应的故障信息时，向所述接收端发送用于通知维修人员对所述运行故障进行手动修复并检查所述运行故障的类型的第二报修信息；
    所述获取装置还用于当所述运行故障修复后，获取所述运行故障的类型和修复方式；
    所述处理器还用于判断所述修复方式是否能通过自动修复实现，得到判断结果；
    并将所述运行故障的类型和所述判断结果进行关联，并存储在所述运行故障数据库中。
  9. 根据权利要求7或8所述的智能监控系统，其特征在于，所述获取装置还用于获取所述机床的编号、所述运行故障的类型和所述机床出现运行故障的时间；
    所述处理器还用于根据所述机床的编号、所述运行故障的类型和所述机床出现运行故障的时间，生成所述机床的运行故障记录表并保存。
  10. 根据权利要求9所述的智能监控系统，其特征在于，所述处理器还用于根据所述运行故障记录表对所述机床出现运行故障的时间、类型和数量进行统计分析，判断在预设时间段内，所述机床的运行故障的数量是否大于预设值；
    所述通信装置还用于当所述机床的运行故障的数量大于预设值时，向所述接收端发送所述机床需要维护的报警信息。
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