CN103786071A - Machine tool working condition real-time monitoring system based on wireless sensor network - Google Patents
Machine tool working condition real-time monitoring system based on wireless sensor network Download PDFInfo
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- CN103786071A CN103786071A CN201410050304.9A CN201410050304A CN103786071A CN 103786071 A CN103786071 A CN 103786071A CN 201410050304 A CN201410050304 A CN 201410050304A CN 103786071 A CN103786071 A CN 103786071A
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 19
- 238000012545 processing Methods 0.000 claims abstract description 23
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/007—Arrangements for observing, indicating or measuring on machine tools for managing machine functions not concerning the tool
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0957—Detection of tool breakage
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0961—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring power, current or torque of a motor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0985—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring temperature
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Abstract
The invention relates to a machine tool working condition real-time monitoring system based on a wireless sensor network. The torque, the temperature of a motor, the cutter loss condition, the workpiece clamping condition and other parameters are measured through a torque sensor, a temperature sensor and other corresponding sensors installed on a machine tool. Data are sent in a wireless and multi-hop routing mode, and after receiving a signal, a single chip microcomputer processes the signal in a simple mode. The single chip microcomputer sends the data to an upper computer, final processing and displaying are carried out through software, and if data are abnormal, an alarm is given in real time, intelligent feedback is achieved, and related actions are carried out for processing. All machine tools in a factory are merged into the network, the networking real-time monitoring of production machines of the factory is achieved, and the monitoring cover degree and real-time performance are greatly improved.
Description
Technical field
The present invention relates to a kind of lathe operating mode real-time monitoring system based on wireless sensor network.
Background technology
In the large production of mechanization now, lathe has become part indispensable in production, its operational factor is larger on production efficiency and production safety impact, if main shaft output torque is the important functional parameter of lathe, if its size has considerable influence to the production of lathe extremely; Cutter directly contacts with workpiece, adds and stressedly goes wrong compared with great Yi man-hour; Motor temperature affects lathe job stability and electrical machinery life; Once the clamping of workpiece does not reach requirement, under the state of High Rotation Speed, easily there is security incident.
On present advanced machine operation interface, there is the real-time demonstration of rotating speed or output torque, but have following drawback: 1. the data parameters that test shows is few, such as tool wear situation, motor temperature, piece-holder situation etc. is measured; 2. show that data are accurate not, only can show the approximate range of torque or rotating speed; 3. the large production operation personnel of batch production are limited, can not accomplish to understand in real time the duty parameter of every lathe.
Summary of the invention
For above-mentioned situation, the present invention discloses a kind of lathe operating mode real-time monitoring system based on wireless sensor network, this device adopts wireless sensor network technology, while utilizing related sensor that lathe is worked, each several part parameter is as output torque, cutter loss, motor temperatures etc. transfer data to total processing center by wireless communication technique, data are processed in real time, in coordinate diagram, the form with figure shows information after treatment simultaneously, realize the running parameter of all lathes of factory is grasped exactly, thereby ensure raising and equipment and the personal safety of production efficiency and the quality of production.
The technical solution adopted for the present invention to solve the technical problems is: a kind of lathe operating mode real-time monitoring system based on wireless sensor network, is characterized in that: comprise parameter measuring apparatus, wireless transmission and receiving system, processing and feedback device.
Described parameter measuring apparatus comprises the torque sensor being arranged on motor transmission shaft, be placed in the three-way piezoelectric sensor of cutter bracketed part, be placed in the temperature sensor of each operation motor internal and be contained in respectively the pressure sensor on three faces that contact with workpiece on scroll chuck.
Wireless transmission and receiving system comprise Motor torque measurement and signal transmitting module, measurement and the signal transmitting module of cutter loss situation, the measurement of machine operation temperature and signal transmitting module, the detection of piece-holder situation and signal transmitting module, and with the wireless receiving module of each signal transmitting module pairing.
Process with feedback device and comprise the control processing module being connected with wireless receiving module and be connected to the displaying alarm of controlling processing module output.
Control the machine motor control end of the output connection of processing module; Displaying alarm comprises seat in the plane terminal and prompting module.
Described parameter measuring apparatus is by sensor collection signal, sensor is as node, signal is sent to single-chip microcomputer Centroid by wireless mode, then Centroid is simply processed passing the signal of coming, send to the host computer place of maincenter processing center, host computer is comprehensively analyzed signal by related software, once discovery signals is abnormal, system intelligence feeds back to relevant portion and takes corresponding actions to process unusual condition.By adopting the mode of wireless transmission, the problem that cannot adopt wired transmission signal and transmit at narrow space, baroque part signal because of High Rotation Speed while having solved well electric machine main shaft work.
Described torque sensor is fixed by screws on workbench, and its one end is connected with motor main shaft by a shaft coupling, and the other end is connected with load equipment by another shaft coupling.
The detection of described piece-holder situation and signal transmitting module are contained in the back side of scroll chuck.
Sensor node includes power module, data acquisition module, single chip processing module and wireless signal transceiver module four module.
Power module uses micro-vibrotechnique generating; When data acquisition module is worked lathe by corresponding sensor and A D, the analog quantity of indices is converted to the digital quantity that can identify for single-chip microcomputer; Single chip processing module is processed every data that acquisition module collection is returned, and deposits its part in external memory storage, controls communicating by letter between wireless transport module and host computer.Wireless transport module is responsible for communicating by letter of single-chip microcomputer and sink node, and is responsible for determining the coding of this sensor.
The invention has the beneficial effects as follows: 1. sensor network is to output torque, cutter loss situation, and the related data monitoring such as motor temperature and piece-holder situation, realize multi-parameter and monitor in real time.
2. by corresponding sensor, data are gathered, send to the host computer of processing center, related software carries out data processing, and data are carried out, after correlation analysis, showing by coordinate diagram form, makes more accurately image of data.
3. in factory, all lathe work informations are all sent to control centre, can accurately understand the working condition of every a machine tool by host computer interface, and networked control makes monitoring comprehensively, in real time, accurately.
Accompanying drawing explanation
Fig. 1 is fundamental diagram of the present invention
Fig. 2 is the mounting structure figure of Motor torque measurement and signal transmitting module
Fig. 3 is the workflow diagram of Motor torque measurement and signal transmitting module
Fig. 4 is the measurement of cutter loss situation and the structure principle chart of signal transmitting module
Fig. 5 is the measurement of cutter loss situation and the workflow diagram of signal transmitting module
Fig. 6 is the measurement of machine operation temperature and the workflow diagram of signal transmitting module
Fig. 7 is the detection of piece-holder situation and the structure principle chart of signal transmitting module
Fig. 8 is the detection of piece-holder situation and the workflow diagram of signal transmitting module
Fig. 9 is the fundamental diagram of sensor node in parameter measuring apparatus
Wherein, the detection of 1-power transmission shaft, 2-shaft coupling, 3-torque sensor, 4-workbench, 5-three-way piezoelectric sensor, 6-cutter cantilever beam, 7-scroll chuck, 8-piece-holder situation and signal transmitting module, 9-pressure sensor.
The specific embodiment
Below in conjunction with accompanying drawing explanation and embodiment, the invention will be further described.
In the first embodiment shown in Fig. 1, Fig. 2, Fig. 3, the measurement of machine motor moment of torsion is carried out as core component to be strain-type wireless torque sensor, and its primary structure increases wireless transmitter module exactly on dynamic torque sensor basis.The strain-type wireless torque sensor volume forming is thus small, simple in structure, have the identical characteristics of dynamic torque sensor, and the non-electric charge quantity signalling collecting can be converted into after electric quantity signal, process control by single-chip microcomputer, signal wireless is transferred to network node place.Torque signal, through the transmission between each node, finally arrives host computer terminal.Host computer is reflected as diagrammatic form by utilization related software by signal, so that staff observes monitoring lathe operating mode, machine torque surveying work completes to this.Excessive when the moment of torsion output of power transmission shaft, displaying alarm sends warning message, controls processing module simultaneously and sends feedback signal to Machine-Tool Control end, and lathe is anxious to stop.
In the second embodiment shown in Fig. 1, Fig. 4, Fig. 5, three-way piezoelectric sensor is placed in the bracketed part of cutter, and lathe cutter in the time of work is stressed, and cutter bracketed part produces deformation, makes foil gauge stressed.Tool wear degree difference, the stressed difference of strain, according to the suffered stress reflection of foil gauge tool wear situation.
The method of testing (as shown in Figure 4) of cutter loss situation: utilize the deformation force that elastic circular ring interference produces that the sensor in the middle of being placed on is clamped, carry out the pretension of sensor, and transmit external force.While carrying out turning experiment, by knife bar tightly on lathe saddle, front end overhang is divided and is equivalent to a cantilever beam, if at cutting force of point of a knife effect, on any main cross section of cantilever beam, be also all subject to an active force that equal and opposite in direction direction is identical, just, due to position, main cross section difference, additional bending moment is different and own.If a three-dimensional force transducer is put into this main cross section according to the direction in figure below and position, just can record Fx, Fy, tri-cutting component of Fz.Piezoelectric quartz sensor in dynamometer is to be made up of the brilliant group of xy cut type and two brilliant groups of yx cut type with shearing effect with pulling and pressed effect, wherein the brilliant group of xy cut type is used for measuring cutting-in drag, and peak response direction is the brilliant group of yx cut type of 90 degree placements mutually for measuring main cutting force and feeding drag.
Three-way piezoelectric sensor detects the abrasion condition of cutter, by sending module, the live signal detecting is sent to wireless receiving module, controls processing module analyzing and processing; When the cutting force of cutter and initial data are when excessive, displaying alarm sends warning message, controls processing module simultaneously and sends feedback signal to spindle motor of machine tool, main shaft stall.
In the 3rd embodiment shown in Fig. 1, Fig. 6, temperature sensor detects the operating temperature of each work drive motor, sending module real-time Transmission signal, displaying alarm shows the operating temperature of each motor, when certain work drive motor temperature anomaly, send control signal by controlling processing module, make this motor out of service.
In the 4th embodiment shown in Fig. 1, Fig. 7, Fig. 8, on three faces that contact with workpiece at scroll chuck, load onto respectively pressure sensor, detect pressure suffered when clamping workpiece, signal is sent to wirelessly to the control section of lathe, receiver receives and makes analysis: 1, judge that whether clamping workpiece is fastening, by pressure sensor measurement data and setting data contrast, if be less than it, lathe cannot start; 2, whether clamping is firm to detect workpiece, analyzes and judges three groups of data, if three data are roughly equal, prove that clamping workpiece is firm, lathe can normally start, if differ larger, lathe can not start, so as not to occur workpiece only with the situation of two claws laminatings.Offer little groove in the body surfaces of scroll chuck, for connecting up, and radio transmission module is contained in to the back side of scroll chuck, signal sensor being recorded by transmitter is sent in network.
In the 5th embodiment shown in Fig. 1, Fig. 9, parameter measuring apparatus is by sensor collection signal, sensor is as node, signal is sent to single-chip microcomputer Centroid by wireless mode, then Centroid is simply processed passing the signal of coming, and sends to the host computer place of maincenter processing center, and host computer is comprehensively analyzed signal by related software, once discovery signals is abnormal, system intelligence feeds back to relevant portion and takes corresponding actions to process unusual condition.
The each sensor node of guarded region is collected every data and is then sent sink point (at wireless sensor network middle finger aggregation node, be mainly responsible for being connected of sensor network and outer net, can regard gateway node as) transmission host computer to and process.
Sensor node includes power module, data acquisition module, single chip processing module and wireless signal transceiver module four module.
Power module uses micro-vibrotechnique generating; When data acquisition module is worked lathe by corresponding sensor and A D, the analog quantity of indices is converted to the digital quantity that can identify for single-chip microcomputer; Single chip processing module is processed every data that acquisition module collection is returned, and deposits its part in external memory storage, controls communicating by letter between wireless transport module and host computer.Wireless transport module is responsible for communicating by letter of single-chip microcomputer and sink node, and is responsible for determining the coding of this sensor.Wireless signal transceiver module intends adopting the wireless signal transceiver of low-power consumption, as CC2520S radiofrequency signal transceiving chip, nRF401 radio transmitting and receiving chip, PTR4000 transceiver module etc., realizes the high-quality low-energy-consumption transmission of signal.
Displaying alarm receives the signal that each node transmission comes, after processing by corresponding software, by after data analysis again host computer display interface show the real-time demonstration of each parameter, control personnel can retrieve for examination the supplemental characteristic of every lathe, facilitate it accurately to understand all sidedly in real time the working condition of the every a machine tool of whole factory, reach the object of real-time monitoring, improve security and the efficiency of producing.
Claims (7)
1. the lathe operating mode real-time monitoring system based on wireless sensor network, is characterized in that: comprise parameter measuring apparatus, wireless transmission and receiving system, processing and feedback device;
Described parameter measuring apparatus comprises the torque sensor being arranged on motor transmission shaft, be placed in the three-way piezoelectric sensor of cutter bracketed part, be placed in the temperature sensor of each operation motor internal and be contained in respectively the pressure sensor on three faces that contact with workpiece on scroll chuck;
Wireless transmission and receiving system comprise Motor torque measurement and signal transmitting module, measurement and the signal transmitting module of cutter loss situation, the measurement of machine operation temperature and signal transmitting module, the detection of piece-holder situation and signal transmitting module, and with the wireless receiving module of each signal transmitting module pairing;
Process with feedback device and comprise the control processing module being connected with wireless receiving module and be connected to the displaying alarm of controlling processing module output.
2. the lathe operating mode real-time monitoring system based on wireless sensor network according to claim 1, is characterized in that: the machine motor control end of controlling the output connection of processing module; Displaying alarm comprises seat in the plane terminal and prompting module.
3. the lathe operating mode real-time monitoring system based on wireless sensor network according to claim 1, it is characterized in that: described parameter measuring apparatus is by sensor collection signal, sensor is as node, signal is sent to single-chip microcomputer Centroid by wireless mode, then Centroid is simply processed passing the signal of coming, send to the host computer place of maincenter processing center, host computer is comprehensively analyzed signal by related software, discovery signals is abnormal, and system intelligence feeds back to relevant portion and takes corresponding actions to process unusual condition.
4. the lathe operating mode real-time monitoring system based on wireless sensor network according to claim 1, it is characterized in that: described torque sensor is fixed by screws on workbench, its one end is connected with motor main shaft by a shaft coupling, and the other end is connected with load equipment by another shaft coupling.
5. the lathe operating mode real-time monitoring system based on wireless sensor network according to claim 1, is characterized in that: the detection of described piece-holder situation and signal transmitting module are contained in the back side of scroll chuck.
6. the lathe operating mode real-time monitoring system based on wireless sensor network according to claim 3, is characterized in that: sensor node includes power module, data acquisition module, single chip processing module and wireless signal transceiver module four module.
7. the lathe operating mode real-time monitoring system based on wireless sensor network according to claim 1, is characterized in that: power module uses micro-vibrotechnique generating; When data acquisition module is worked lathe by corresponding sensor and A D, the analog quantity of indices is converted to the digital quantity that can identify for single-chip microcomputer; Single chip processing module is processed every data that acquisition module collection is returned, and deposits its part in external memory storage, controls communicating by letter between wireless transport module and host computer; Wireless transport module is responsible for communicating by letter of single-chip microcomputer and sink node, and is responsible for determining the coding of this sensor.
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Cited By (20)
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| CN104139322A (en) * | 2014-07-18 | 2014-11-12 | 哈尔滨工业大学 | Capacitive intelligent knife handle system for detection of four-dimensional cutting force |
| CN104308661A (en) * | 2014-10-08 | 2015-01-28 | 烟台拓伟机械有限公司 | Disc type part numerical control turning processing dimension on-line measurement device |
| CN104407597A (en) * | 2014-12-12 | 2015-03-11 | 东莞市豪斯特热冲压技术有限公司 | Intelligent problem handling system for automatic production line |
| CN104504877A (en) * | 2014-12-05 | 2015-04-08 | 上海交通大学 | Wireless measuring system for real-time torque of machine tool spindle |
| CN104669057A (en) * | 2015-01-31 | 2015-06-03 | 重庆大学 | Additional load loss coefficient acquiring method of machining system of machine tool |
| CN105913640A (en) * | 2016-05-24 | 2016-08-31 | 北京工业大学 | Wireless receiving/transmitting control system of strain measured data of chuck |
| CN106002486A (en) * | 2016-07-27 | 2016-10-12 | 大连理工大学 | Micro-milling force measuring method based on micro-milling machine main drive system power |
| CN106094723A (en) * | 2016-05-26 | 2016-11-09 | 清华大学深圳研究生院 | The monitoring of a kind of machine tool temperature field based on WSN and in real time heat error compensation system |
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| CN104504877B (en) * | 2014-12-05 | 2018-02-09 | 上海交通大学 | A kind of real-time moment of torsion wireless measuring system of machine tool chief axis |
| CN108981826A (en) * | 2018-09-12 | 2018-12-11 | 成都安尔法智控科技有限公司 | Three shaft vibrations and temperature monitoring sensor |
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| CN112571152A (en) * | 2019-09-30 | 2021-03-30 | 江苏西格数据科技有限公司 | Monitoring system for be used for detecting cutter state |
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Cited By (26)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104139322A (en) * | 2014-07-18 | 2014-11-12 | 哈尔滨工业大学 | Capacitive intelligent knife handle system for detection of four-dimensional cutting force |
| CN104139322B (en) * | 2014-07-18 | 2016-06-29 | 哈尔滨工业大学 | A kind of condenser type intelligence handle of a knife system for the detection of four-dimensional cutting power |
| CN104308661A (en) * | 2014-10-08 | 2015-01-28 | 烟台拓伟机械有限公司 | Disc type part numerical control turning processing dimension on-line measurement device |
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