CN104503362B - Batch workpiece digital control processing progress automatic acquiring method based on Multi-information acquisition - Google Patents
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Abstract
本发明提供一种基于多信息融合的批量工件数控加工进度自动采集方法。通过网线将机床数控系统与计算机终端相连，并通过接口程序读取并处理得到加工启停信息；另外，在机床电机和变频器之间引入功率传感器，功率传感器通过模/数转换模块与计算机终端连接采集加工中的实时功率信息；通过与质量检测系统通信获取加工中的加工质量信息；根据上述获得的加工启停信息、实时功率信息和加工质量信息，并自动进行综合处理，得到加工过程中的进度数据。本发明具有反馈及时、统计准确、统计内容丰富等优点，可以为提高企业对生产现场的管控能力及加工车间的优化运行提供支持，也方便让客户随时监控订单的执行情况，提高对客户的服务能力。
The invention provides a method for automatically collecting the progress of numerical control machining of batch workpieces based on multi-information fusion. Connect the CNC system of the machine tool with the computer terminal through the network cable, and read and process the processing start-stop information through the interface program; in addition, a power sensor is introduced between the machine tool motor and the frequency converter, and the power sensor is connected to the computer terminal through the analog/digital conversion module Connect to collect real-time power information during processing; obtain processing quality information during processing through communication with the quality inspection system; process start-stop information, real-time power information and processing quality information obtained above, and automatically carry out comprehensive processing to obtain processing quality information during processing. progress data. The invention has the advantages of timely feedback, accurate statistics, rich statistical content, etc. It can provide support for improving the management and control capabilities of enterprises on the production site and the optimized operation of processing workshops. It is also convenient for customers to monitor the execution of orders at any time and improve customer service. ability.
Description
技术领域technical field
本发明涉及到机械制造业、网络与通讯技术、信息处理技术领域，属于制造执行系统中信息采集及信号处理方法，具体涉及一种基于多信息融合的批量工件数控加工进度自动采集方法。The invention relates to the fields of machinery manufacturing, network and communication technology, and information processing technology, and belongs to information collection and signal processing methods in a manufacturing execution system, in particular to a method for automatically collecting batch workpiece numerical control processing progress based on multi-information fusion.
背景技术Background technique
加工车间在制工件的实际加工进度信息反馈了当前加工任务的完成状况，工件的加工进度状态，反映了车间各机床的任务分配及加工情况，反映了制造企业现有设备的加工性能和效率、零件的加工精度及订单产品完成的情况等信息，这些数据信息是机械制造工艺规划人员和生产管理调度人员优化生产管理及调度过程的基础，另外客户也需要随时了解订单的执行状况。现代制造企业必须具有对这些不确定性因素的快速反应和处理能力，这样才能维持和提高现代企业的业务竞争力。必须采集工件的加工进度状态信息，以方便车间的操作人员及企业的管理和调度人员适时掌握工件的加工进度信息，同时也方便客户随时查询订单执行情况。The actual processing progress information of the workpiece in the processing workshop feeds back the completion status of the current processing task. The processing progress status of the workpiece reflects the task allocation and processing status of each machine tool in the workshop, and reflects the processing performance and efficiency of the existing equipment of the manufacturing enterprise. The processing accuracy of parts and the completion status of ordered products are the basis for mechanical manufacturing process planners and production management dispatchers to optimize production management and scheduling processes. In addition, customers also need to know the status of order execution at any time. Modern manufacturing enterprises must have the ability to quickly respond and deal with these uncertain factors, so as to maintain and improve the business competitiveness of modern enterprises. It is necessary to collect the status information of the processing progress of the workpiece, so that the operators in the workshop and the management and scheduling personnel of the enterprise can grasp the processing progress information of the workpiece in a timely manner, and it is also convenient for customers to query the order execution status at any time.
传统生产加工进度信息采集主要依赖操作人员进行目测、清点、统计，手工填写纸质文件。这种方式依靠手操作，人员填写效率低下，工作内容重复繁琐，信息的准确度受人为因素影响，不稳定而且数据不利于传输与共享。此外，纸质文件很容易损坏，数据的保存和查询难度相对较大；而且，车间中经常会出现多个不同的工件在一段时间内同时在一台机床上加工的现象，这也给统计带来一定的复杂性。随着现代企业的生产自动化水平的提高，企业已经广泛采用计算机来处理和管理生产，这种人工统计方式已经满足不了现代企业的需要。另外，目前，虽然在部分自动化程度较高的车间中，已采用条形码、RFID、PLC、NC代码中插入宏指令等方式，实现了生产加工进度信息的自动采集及上报，但是上述方法都只是简单采集累计加工的件数，而对于加工中具体的正常加工件数、返工加工件数、合格品数等重要的进度信息难于自动进行统计，这就不能很好的为企业的优化运行提供支持。The collection of traditional production and processing progress information mainly relies on operators to conduct visual inspection, inventory, statistics, and manually fill in paper documents. This method relies on manual operation, the efficiency of personnel filling is low, the work content is repetitive and cumbersome, the accuracy of information is affected by human factors, unstable and the data is not conducive to transmission and sharing. In addition, paper files are easily damaged, and data storage and query are relatively difficult; moreover, it is often the case that many different workpieces are processed on one machine tool at the same time in the workshop, which also brings a negative impact on statistics. Come a certain complexity. With the improvement of the production automation level of modern enterprises, enterprises have widely used computers to process and manage production. This manual statistical method can no longer meet the needs of modern enterprises. In addition, at present, although in some workshops with a high degree of automation, barcodes, RFID, PLC, and NC codes have been used to insert macro instructions into the code to realize the automatic collection and reporting of production and processing progress information, but the above methods are only simple. Collect the cumulative number of processed pieces, but it is difficult to automatically count important progress information such as the number of normal processed pieces, the number of reworked pieces, and the number of qualified products during processing, which cannot provide support for the optimal operation of the enterprise.
发明内容Contents of the invention
针对目前车间工件加工进度信息主要靠人工统计，虽然可通过条形码、RFID、PLC、NC代码中插入宏指令等方式获得加工的进度信息，但由于数控加工过程存在试切、返工、报废等多种复杂情况，常常会造成加工数量统计的冗余，导致生产进度信息获取不准确等问题，本发明的目的是提供一种数据反馈及时、统计准确、统计内容丰富、降低人力成本的基于多信息融合的批量工件数控加工进度自动采集方法。In view of the fact that the processing progress information of workpieces in the workshop is mainly based on manual statistics, although the processing progress information can be obtained by inserting macro instructions into barcodes, RFID, PLC, and NC codes, due to the existence of trial cutting, rework, scrapping, etc. Complicated situations often lead to redundant statistics of processing quantities, resulting in inaccurate acquisition of production progress information and other issues. The purpose of the present invention is to provide a multi-information fusion-based system with timely data feedback, accurate statistics, rich statistical content and reduced labor costs. The automatic acquisition method of batch workpiece CNC machining progress.
实现上述目的，本发明采用如下技术方案：一种基于多信息融合的批量工件数控加工进度自动采集方法，其特征在于，根据批量工件数控加工过程中，对机床数控程序中包含的加工启停信息，加工过程的功率信息以及工件抽检获取的质量信息进行多信息的融合处理，得到准确、丰富的加工进度信息。To achieve the above object, the present invention adopts the following technical scheme: a method for automatically collecting the progress of CNC machining of batch workpieces based on multi-information fusion, which is characterized in that, according to the process of CNC machining of batch workpieces, the processing start-stop information contained in the CNC program of the machine tool , the power information of the processing process and the quality information obtained by the workpiece sampling inspection are processed by multi-information fusion to obtain accurate and rich processing progress information.
进一步，所述自动采集进度信息的步骤为：Further, the step of automatically collecting progress information is:
①利用计算机或嵌入式终端，通过接口程序采集机床数控程序中的加工启停信息，一次循环启停则实际加工数+1；① Use a computer or an embedded terminal to collect the processing start and stop information in the CNC program of the machine tool through the interface program, and the actual processing number will be +1 when a cycle is started and stopped;
②加工过程中，通过网络通信实时采集加工该工件的功率信息并进行分析处理，并与功率信息标准进行比较：若处于正常加工的范围，则正常加工数+1；否则返工加工数+1；②During the processing, the power information of the workpiece is collected and processed in real time through network communication, analyzed and processed, and compared with the power information standard: if it is within the normal processing range, the number of normal processing is +1; otherwise, the number of rework processing is +1;
如果还没有设置功率信息标准，则对当前工件进行检验，如果合格，则把该工件的功率信息作为后续加工进行比较的功率信息标准；If the power information standard has not been set, the current workpiece is inspected, and if it is qualified, the power information of the workpiece is used as the power information standard for comparison in subsequent processing;
③通过网络通信获取质量检测得到的质量信息，进行质量状态的判断从而得到加工过程中合格品数，报废品数，需返工加工数的统计；③ Obtain the quality information obtained by quality inspection through network communication, and judge the quality state to obtain the statistics of the number of qualified products, the number of scrapped products, and the number of reworked products in the processing process;
④综合第①步到第③步，第①步得到该次任务的实际加工数量，第②步是对第①步得到的实际加工数量进行更加准确的分类，通过对加工每个工件的功率信息进行分析处理获取实际加工工件中正常加工件与返工加工件的数量，第③步通过工件质量信息获取本任务实际加工件的质量情况，得到该任务中工件的合格品数，报废品数，需返工加工数；④Integrating step ① to step ③, step ① obtains the actual processing quantity of the task, step ② is to classify the actual processing quantity obtained in step ① more accurately, and process each workpiece through power information Perform analysis and processing to obtain the number of normal processed parts and reworked parts in the actual processed workpieces. Step ③ obtains the quality of the actual processed parts of this task through the workpiece quality information, and obtains the number of qualified products, the number of scrapped products, and the number of reworked parts in the task. number;
⑤用合格品数/计划加工数得到本加工任务的完成率；⑤ Obtain the completion rate of this processing task by the number of qualified products/planned processing number;
综上，通过本方法可以得到加工过程中的以下进度信息：实际加工数，合格品数，正常加工数，返工加工数，需返工加工数，报废品数，加工任务完成率。In summary, the following progress information in the processing process can be obtained through this method: the actual processing number, the number of qualified products, the number of normal processing, the number of reworked processing, the number of reworked processing, the number of scrapped products, and the completion rate of processing tasks.
相比现有技术，本发明具有如下有益效果：Compared with the prior art, the present invention has the following beneficial effects:
1、本发明方法操作简单、稳定且成本较低，不影响正常加工。1. The method of the present invention is simple, stable and low in cost, and does not affect normal processing.
2、本发明具有数据反馈及时、统计准确、统计内容丰富等优点，将加工启停信息，功率信息以及质量信息进行多信息融合处理采集到的进度信息不仅包括实际加工件数，而且包括正常加工工件数量、返工加工工件数量、合格品数量、报废数量和需返工数量等信息，这可以为提高企业对生产现场的管控能力及加工车间的优化运行提供支持，也方便让客户随时监控订单的执行情况，提高对客户的服务能力。2. The present invention has the advantages of timely data feedback, accurate statistics, and rich statistical content. The progress information collected through multi-information fusion processing of processing start-stop information, power information, and quality information includes not only the actual number of pieces processed, but also the number of normally processed workpieces. Quantity, reworked workpiece quantity, qualified product quantity, scrapped quantity and reworked quantity and other information, which can provide support for improving the management and control ability of the production site and the optimized operation of the processing workshop, and it is also convenient for customers to monitor the execution of orders at any time , Improve customer service capabilities.
3、加工启停信息，质量信息和功率信息的采集和分析都可采用自动化软件在线进行,因此这种方法适合在自动化制造系统中应用。3. The collection and analysis of processing start-stop information, quality information and power information can be carried out online by using automation software, so this method is suitable for application in automated manufacturing systems.
经实践检验，该方法是有效且可行的。利用本发明将解决生产进度信息提取困难、准确度难于保证、信息实时性差、容易出差错、浪费人力资源等问题，从而提高企业对生产现场的管控能力以及增加企业效益。It has been verified by practice that this method is effective and feasible. Utilizing the invention will solve the problems of difficulty in extracting production schedule information, difficulty in ensuring accuracy, poor real-time information, easy errors, waste of human resources, etc., thereby improving the ability of enterprises to control production sites and increasing enterprise benefits.
附图说明Description of drawings
图1是本发明方法原理框图。Fig. 1 is a schematic block diagram of the method of the present invention.
图2是本发明方法进度自动采集流程图；Fig. 2 is the flow chart of automatic acquisition of method progress of the present invention;
图3是本发明方法中数控程序启停信息采集处理框图；Fig. 3 is a block diagram of information acquisition and processing of the start-stop information of the numerical control program in the method of the present invention;
图4是本发明方法中功率信息采集处理框图；Fig. 4 is a block diagram of power information collection and processing in the method of the present invention;
图5是本发明方法中质量信息采集处理框图。Fig. 5 is a block diagram of quality information collection and processing in the method of the present invention.
具体实施方式detailed description
下面结合附图和具体实施例对本发明做进一步说明。The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.
参见图1，本发明基于多信息融合的批量工件数控加工进度自动采集方法，根据批量工件数控加工过程中，对机床数控程序中包含的加工启停信息，加工过程的功率信息以及工件抽检获取的质量信息进行多信息的融合处理，得到准确、丰富的进度信息。通过网线将机床数控系统与计算机终端相连，并通过接口程序读取并处理得到加工启停信息，另外在机床电机和变频器之间引入功率传感器，功率传感器通过模/数转换模块与计算机终端连接采集加工中的实时功率信息，最后，通过与质量检测系统通信获取加工中的质量信息，根据图2所示的流程进行数据处理，得到加工过程中的进度信息。Referring to Fig. 1, the present invention is based on the multi-information fusion automatic acquisition method of batch workpiece CNC machining progress, according to the process of batch workpiece CNC machining, the processing start-stop information included in the machine tool CNC program, the power information of the machining process and the workpiece sampling inspection. The quality information is fused with multiple information to obtain accurate and rich progress information. Connect the CNC system of the machine tool with the computer terminal through the network cable, and read and process the processing start-stop information through the interface program. In addition, a power sensor is introduced between the machine tool motor and the frequency converter, and the power sensor is connected to the computer terminal through the analog/digital conversion module. Collect real-time power information during processing, and finally, obtain quality information during processing by communicating with the quality inspection system, and process data according to the flow shown in Figure 2 to obtain progress information during processing.
实施例1：Example 1:
加工工件：齿轮；Processing workpiece: gear;
机床：YS3118CNC5五轴数控高速滚齿机；Machine tool: YS3118CNC5 five-axis CNC high-speed gear hobbing machine;
传感器：WBQ212P71；Sensor: WBQ212P71;
终端：iTouch121A(-T)嵌入式信息终端；Terminal: iTouch121A(-T) embedded information terminal;
模/数转换器：HTK-NDC1以太网现场测控服务器；Analog/digital converter: HTK-NDC1 Ethernet field measurement and control server;
滚齿批量加工进度自动采集流程参见图2所示，加床运行后开始加工，加工过程中通过接口程序获取数控程序中的加工启停信息；一次循环启停则实际加工件数增加1，另外对本次加工的功率信息进行分析处理，并与标准功率信息（如果还没有设置标准，则对该工件进行检验，如果合格就把处理后的该工件的功率信息设为标准）进行比对，得到本次加工更加准确的加工情况(正常加工，返工加工)，也即对上一步得到的实际加工数做出更加准确的分类（正常加工数、返工加工数）。如果通过质检系统检测到质量信息，那么就对质量信息进行处理，得到加工的合格品数，报废品数，返工加工件数。综合三方面的信息并进行处理，最后得到准确丰富的进度信息。最后终端将实时进度数据上传到企业计划管理部门，使上层实时了解车间生产状况并进行优化调度。The process of automatic collection of gear hobbing batch processing progress is shown in Figure 2. After the extra bed is running, the processing starts. During the processing, the processing start and stop information in the NC program is obtained through the interface program; the actual number of pieces processed will increase by 1 when the cycle is started and stopped. The power information of this processing is analyzed and processed, and compared with the standard power information (if the standard has not been set, the workpiece is inspected, and if it is qualified, the power information of the processed workpiece is set as the standard), and the obtained The more accurate processing status of this processing (normal processing, rework processing), that is, to make a more accurate classification of the actual processing number obtained in the previous step (normal processing number, rework processing number). If the quality information is detected through the quality inspection system, then the quality information is processed to obtain the number of processed qualified products, the number of scrapped products, and the number of reworked pieces. The three aspects of information are integrated and processed, and finally accurate and rich progress information is obtained. Finally, the terminal uploads the real-time progress data to the enterprise planning management department, so that the upper layer can understand the production status of the workshop in real time and optimize the scheduling.
数控程序启停信息采集处理流程如图3所示，通过接口程序采集数控代码中的启停信号，再通过程序将采集到的信号传给进度监视系统进行数据处理。The process of collecting and processing the start-stop information of the NC program is shown in Figure 3. The start-stop signal in the NC code is collected through the interface program, and then the collected signal is transmitted to the progress monitoring system through the program for data processing.
功率信息采集处理流程如图4所示，能效监控系统通过读取并处理功率传感器采集到的功率值，将处理得到的结果通过socket通信的方式传给进度监视系统进行数据的处理。The power information collection and processing flow is shown in Figure 4. The energy efficiency monitoring system reads and processes the power value collected by the power sensor, and transmits the processing result to the progress monitoring system through socket communication for data processing.
质量信息的采集处理流程如图5所示，质量数据采集系统通过数显量具量仪接口、人工录入接口或者从其他系统导入等方式获取工件的实时质量数据,然后对这些质量数据进行分析处理,得到工件的质量状态：合格、报废、返工，然后将这个状态传送给进度监视系统，进行进度数据的判断处理。The collection and processing flow of quality information is shown in Figure 5. The quality data collection system obtains the real-time quality data of the workpiece through the digital display measuring tool interface, manual input interface, or import from other systems, and then analyzes and processes these quality data. Get the quality status of the workpiece: pass, scrap, rework, and then transmit this status to the progress monitoring system to judge and process the progress data.
最后说明的是，以上实施例仅用以说明本发明的技术方案而非限制，尽管参照较佳实施例对本发明进行了详细说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的宗旨和范围，其均应涵盖在本发明的权利要求范围当中。Finally, it is noted that the above embodiments are only used to illustrate the technical solutions of the present invention without limitation. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be carried out Modifications or equivalent replacements without departing from the spirit and scope of the technical solution of the present invention shall be covered by the claims of the present invention.
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