CN111168470A - Machine tool cutter fault testing system - Google Patents
Machine tool cutter fault testing system Download PDFInfo
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- CN111168470A CN111168470A CN201811336524.2A CN201811336524A CN111168470A CN 111168470 A CN111168470 A CN 111168470A CN 201811336524 A CN201811336524 A CN 201811336524A CN 111168470 A CN111168470 A CN 111168470A
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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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- 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
- B23Q17/0971—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 mechanical vibrations of parts of the machine
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Abstract
一种机床刀具故障测试系统，利用中央处理器、振动传感器、信号处理电路、温度传感器、湿度传感器、图像采集模块、图像处理模块、电源模块、比较模块、报警装置、无线传输装置、用户手机、显示装置以及存储装置，可实现对数控机床在作业时的刀具的有效监测，不仅能够通过振动传感器测试刀具在加工过程中的振动参数，并将该振动参数与预设振动阈值进行比较，还能通过图像采集模块采集刀具的图像信息，工作人员能够结合振动传感器采集的刀具振动信号和刀具图像信息对数控机床的刀具进行有效监测，避免发生误判。
A machine tool fault testing system, using a central processing unit, a vibration sensor, a signal processing circuit, a temperature sensor, a humidity sensor, an image acquisition module, an image processing module, a power supply module, a comparison module, an alarm device, a wireless transmission device, a user mobile phone, The display device and the storage device can effectively monitor the tools of the CNC machine tool during operation. Not only can the vibration parameters of the tools be tested during the machining process through the vibration sensor, and the vibration parameters can be compared with the preset vibration threshold. The image information of the tool is collected by the image acquisition module, and the staff can effectively monitor the tool of the CNC machine tool by combining the tool vibration signal collected by the vibration sensor and the tool image information to avoid misjudgment.
Description
Technical Field
The invention relates to the technical field of intelligent testing, in particular to a fault testing system for a machine tool cutter.
Background
A numerical control machine tool is a short name for digital control machine tools (Computer numerical control machine tools) and is an automated machine tool equipped with a program control system that is capable of logically processing and decoding a program specified by a control code or other symbolic command, expressing the decoded program in a coded number, and inputting the coded number to a numerical control device via an information carrier. After operation, the numerical control device sends out various control signals to control the action of the machine tool, and the parts are automatically machined according to the shape and the size required by the drawing. The numerical control machine tool well solves the problem of machining of complex, precise, small-batch and various parts, is a flexible and high-efficiency automatic machine tool, represents the development direction of the control technology of modern machine tools, and is a typical mechanical and electrical integration product.
The cutter system is an extremely important functional part of a high-grade numerical control machine tool, in the cutting process, a cutter works under the conditions of high temperature and high pressure, due to severe friction of workpieces and chips, abrasion can be generated in the front and back contact areas, when the abrasion is light, the geometric shape of the cutter and the size of a processed workpiece can be changed, and the phenomena of cutter failure such as cutter abrasion, breakage, cutting edge plastic deformation, thermal abrasion and the like can be caused seriously, so that the processing quality and the production efficiency of products are greatly reduced. Therefore, it is very important to perform online monitoring and early warning on the tool wear condition of the numerical control machine tool to reduce the tool failure phenomenon. The detection of the cutter is divided into direct detection and indirect detection, the cutter needs to be taken down from a numerical control machine tool by the direct detection method, the machining efficiency of the numerical control machine tool is further influenced, the indirect detection has the advantages of real-time performance, convenience and the like, but the precision of a test result obtained by using the indirect detection method is not high due to different machining environments of the numerical control machine tool.
Disclosure of Invention
Therefore, in order to overcome the above problems, the present invention provides a machine tool failure testing system, which utilizes a central processing unit, a vibration sensor, a signal processing circuit, a temperature sensor, a humidity sensor, an image acquisition module, an image processing module, a power supply module, a comparison module, an alarm device, a wireless transmission device, a user mobile phone, a display device and a storage device, to realize effective monitoring of the tool of a numerical control machine tool during operation, not only can test the vibration parameter of the tool during the processing process through the vibration sensor and compare the vibration parameter with a preset vibration threshold, but also can acquire the image information of the tool through the image acquisition module, and a worker can effectively monitor the tool of the numerical control machine tool by combining the tool vibration signal acquired by the vibration sensor and the tool image information, so as to avoid erroneous judgment, and simultaneously, the influence of the environment temperature and the humidity on the tool during the machine tool operation cannot be ignored, therefore, the temperature and humidity of the environment during the operation of the machine tool can be detected by using the temperature sensor and the humidity sensor, so that the working personnel can timely know the temperature and humidity information of the environment during the operation of the machine tool.
According to the machine tool cutter fault testing system, the machine tool cutter fault testing system comprises a central processing unit, a vibration sensor, a signal processing circuit, a temperature sensor, a humidity sensor, an image acquisition module, an image processing module, a power supply module, a comparison module, an alarm device, a wireless transmission device, a user mobile phone, a display device and a storage device.
The image acquisition module is used for acquiring image information of a cutter of a machine tool during operation, the vibration sensor is used for acquiring vibration signals of the cutter of the machine tool during operation, the output end of the vibration sensor is connected with the input end of the signal processing circuit, the output end of the image acquisition module is connected with the input end of the image processing module, the output end of the signal processing circuit, the output end of the temperature sensor, the output end of the humidity sensor, the output end of the image processing module and the output end of the power supply module are respectively connected with the input end of the central processing unit, the output end of the comparison module is connected with the input end of the alarm device, the input end of the comparison module, the input end of the display device and the input end of the storage device are respectively connected with the output end of the central processing unit.
Preferably, the vibration sensor is used for collecting vibration signals of a tool during operation of the machine tool, converting the collected vibration signals into voltage signals V0 and transmitting the voltage signals V0 to the signal processing circuit, V1 is voltage signals processed by the signal processing circuit, the signal processing circuit comprises a signal amplifying unit and a signal filtering unit, an output end of the vibration sensor is connected with an input end of the signal amplifying unit, an output end of the signal amplifying unit is connected with an input end of the signal filtering unit, and an output end of the signal filtering unit is connected with an ADC port of the central processing unit.
Preferably, the signal amplifying unit includes integrated operational amplifiers a1-A3 and resistors R1-R14.
Wherein, the output end of the vibration sensor is connected with one end of a resistor R1, the other end of the resistor R1 is connected with one end of a resistor R2, the other end of a resistor R1 is further connected with one end of a resistor R3, the other end of the resistor R3 is grounded, the other end of a resistor R2 is connected with one end of a resistor R4, the other end of a resistor R4 is grounded, the other end of a resistor R2 is further connected with the non-inverting input end of an integrated operational amplifier a1, one end of a resistor R5 is grounded, the other end of a resistor R5 is connected with one end of a resistor R6, the other end of a resistor R6 is connected with the inverting input end of an integrated operational amplifier a1, the other end of a resistor R5 is further connected with one end of a resistor R7, the output end of an integrated operational amplifier a1 is connected with one end of a resistor R10, the other end of a resistor R10 is grounded, the output end of an integrated operational amplifier a1 is further connected with the non-inverting input end of an integrated operational, the other end of the resistor R8 is further connected with one end of the resistor R9, the other end of the resistor R7 is connected with the other end of the resistor R9 in parallel and then connected with the output end of the integrated operational amplifier A2, the output end of the integrated operational amplifier A2 is further connected with one end of the resistor R11, the other end of the resistor R11 is grounded, the output end of the integrated operational amplifier A2 is further connected with one end of the resistor R12, the other end of the resistor R12 is connected with the non-inverting input end of the integrated operational amplifier A3, one end of the resistor R14 is connected with the inverting input end of the integrated operational amplifier A3, the other end of the resistor R14 is connected with the output end of the integrated operational amplifier A3, one end of the resistor R14 is further connected with one end of the resistor.
Preferably, the signal filtering unit comprises resistors R15-R21, capacitors C1-C2 and an integrated operational amplifier A4-A6.
Wherein, the output end of the signal amplifying unit is connected with one end of a resistor R15, the other end of a resistor R15 is connected with one end of a resistor R17 in parallel and then connected with the non-inverting input end of an integrated operational amplifier A4, the other end of a resistor R17 is connected with the output end of an integrated operational amplifier A4, one end of a resistor R16 is grounded, the other end of a resistor R16 is connected with a resistor R21 in parallel and then connected with the non-inverting input end of an integrated operational amplifier A4, the other end of a resistor R21 is connected with the output end of an integrated operational amplifier A5, the other end of a resistor R17 is connected with the output end of an integrated operational amplifier A4 in parallel and then connected with one end of a resistor R18, the other end of a resistor R18 is connected with one end of a capacitor C1 in parallel and then connected with the inverting input end of an integrated operational amplifier A5, the other end of a capacitor C1 is connected with the output end of an integrated operational amplifier A5 in parallel and then connected with one end of a resistor R19, the non-, the non-inverting input end of the integrated operational amplifier A6 is grounded, the other end of the capacitor C2 is connected with the output end of the integrated operational amplifier A6, one end of the resistor R20 is connected with the inverting input end of the integrated operational amplifier A4, the other end of the resistor R20 is connected with the output end of the integrated operational amplifier A6, one end of the resistor R21 is connected with the non-inverting input end of the integrated operational amplifier A4, the other end of the resistor R21 is connected with the output end of the integrated operational amplifier A5, the output end of the integrated operational amplifier A6 is connected with the ADC port of the central processing unit, and the signal processing unit transmits the processed voltage signal V1 to the ADC port of the central processing unit.
Preferably, the image processing module includes an image denoising unit, an image enhancing unit, an image sharpening unit, and an image smoothing unit.
The image acquisition module is used for acquiring image information of a cutter of a machine tool during operation, the output end of the image acquisition module is connected with the input end of the image noise reduction unit, the output end of the image noise reduction unit is connected with the input end of the image enhancement unit, the output end of the image enhancement unit is connected with the input end of the image sharpening unit, the output end of the image sharpening unit is connected with the input end of the image smoothing unit, and the output end of the image smoothing unit is connected with the input end of the central processing unit.
Preferably, the image acquisition module is used for acquiring image information of a tool of the machine tool during operation, the vibration sensor is used for acquiring a vibration signal of the tool of the machine tool during operation, the temperature sensor is used for acquiring an ambient temperature signal of the machine tool during operation, and the humidity sensor is used for acquiring an ambient humidity signal of the machine tool during operation.
The vibration signal of the tool is transmitted to the signal processing circuit when the vibration sensor works, the signal processing circuit sequentially amplifies and filters the received vibration signal, the processed vibration signal is transmitted to an ADC (analog to digital converter) port of the central processing unit, the central processing unit transmits the received vibration signal to the display device for displaying, the central processing unit transmits the received vibration signal to the storage device for storage, the central processing unit transmits the received vibration signal to a user mobile phone through the wireless transmission device, the central processing unit transmits the received vibration signal to the comparison module, the comparison module compares the received vibration signal with a preset vibration threshold value, and if the vibration signal received by the comparison module is larger than the preset vibration threshold value, the alarm device sends alarm information.
The image acquisition module transmits acquired image information of a cutter of the machine tool during operation to the image processing module, the image processing module performs image processing on the received image information and transmits the processed image information to the central processing unit, the central processing unit transmits the received image information to the display device for display, the central processing unit transmits the received image information to the storage device for storage, and the central processing unit transmits the received image information to a mobile phone of a user through the wireless transmission device; the temperature sensor is used for acquiring an ambient temperature signal of the machine tool during operation, the temperature sensor transmits the acquired ambient temperature signal of the machine tool during operation to the central processing unit, the central processing unit transmits the received ambient temperature signal of the machine tool during operation to the display device for display, the central processing unit transmits the received ambient temperature signal of the machine tool during operation to the storage device for storage, and the central processing unit transmits the received ambient temperature signal of the machine tool during operation to a mobile phone of a user through the wireless transmission device; the humidity sensor is used for collecting an environment humidity signal of the machine tool during operation, the humidity sensor transmits the collected environment humidity signal of the machine tool during operation to the central processing unit, the central processing unit transmits the received environment humidity signal of the machine tool during operation to the display device for display, the central processing unit transmits the received environment humidity signal of the machine tool during operation to the storage device for storage, and the central processing unit transmits the received environment humidity signal of the machine tool during operation to the mobile phone of a user through the wireless transmission device.
Preferably, the image of the tool during operation of the machine tool, which transmits the image acquisition module to the image processing module, is defined as a two-dimensional function f (x, y), where x and y are space coordinates, the image denoising unit performs image denoising on the image f (x, y), and the two-dimensional function of the image after the image denoising is g (x, y), where g (x, y) is the two-dimensional function of the image after the image denoising is performed
Preferably, the image enhancement unit performs image sharpness enhancement processing on the image g (x, y), and a two-dimensional function of the image after the image sharpness enhancement processing is h (x, y), wherein,
preferably, the image sharpening unit performs an image sharpening process on the image h (x, y), and the two-dimensional function of the image after the image sharpening process is d (x, y), wherein,
preferably, the image smoothing unit performs image smoothing on the image d (x, y), the two-dimensional function of the image after the image smoothing is s (x, y), the smoothing function is q (x, y),
where ﹡ is a convolution symbol,
for self-defining adjustable constants, smoothing is effected by
To be controlled.
The image smoothing unit transmits the image s (x, y) to the central processor.
Preferably, the power module provides power support for the central processing unit.
Preferably, the image acquisition module is a CCD image sensor, and the vibration sensor is a compression-type acceleration sensor for testing.
Compared with the prior art, the invention has the following beneficial effects:
(1) the invention provides a machine tool cutter fault testing system, which utilizes a central processing unit, a vibration sensor, a signal processing circuit, a temperature sensor, a humidity sensor, an image acquisition module, an image processing module, a power supply module, a comparison module, an alarm device, a wireless transmission device, a user mobile phone, a display device and a storage device to realize effective monitoring of a cutter of a numerical control machine tool during operation, can test vibration parameters of the cutter during the processing process through the vibration sensor and compare the vibration parameters with a preset vibration threshold value, can also acquire image information of the cutter through the image acquisition module, can effectively monitor the cutter of the numerical control machine tool by combining a cutter vibration signal acquired by the vibration sensor and the cutter image information, avoids erroneous judgment, and simultaneously, the influence of the environment temperature and humidity on the cutter during the machine tool operation is not neglected, therefore, the temperature and the humidity of the environment during the operation of the machine tool are detected by using the temperature sensor and the humidity sensor, so that the working personnel can timely acquire the temperature and the humidity information of the environment during the operation of the machine tool;
(2) according to the machine tool cutter fault testing system provided by the invention, the image processing module sequentially performs image enhancement, image smoothing, image sharpening and image gray level conversion processing on the acquired image, so that the image information of the image acquisition module can be efficiently and quickly extracted, the identification precision of the cutter image can be improved, and the occurrence of misjudgment conditions can be effectively reduced.
Drawings
Fig. 1 is a schematic diagram of a machine tool failure testing system of the present invention.
Fig. 2 is a circuit diagram of a signal processing circuit according to the present invention.
FIG. 3 is a diagram of an image processing module according to the present invention.
Reference numerals:
1-a central processing unit; 2-a vibration sensor; 3-a signal processing circuit; 4-a temperature sensor; 5-a humidity sensor; 6-an image acquisition module; 7-an image processing module; 8-a power supply module; 9-a comparison module; 10-an alarm device; 11-a wireless transmission device; 12-a user handset; 13-a display device; 14-storage means.
Detailed Description
The following describes the machine tool failure testing system provided by the invention in detail with reference to the accompanying drawings and embodiments.
As shown in fig. 1, the machine tool fault testing system provided by the invention comprises a central processing unit 1, a vibration sensor 2, a signal processing circuit 3, a temperature sensor 4, a humidity sensor 5, an image acquisition module 6, an image processing module 7, a power supply module 8, a comparison module 9, an alarm device 10, a wireless transmission device 11, a user mobile phone 12, a display device 13 and a storage device 14.
Wherein, the image acquisition module 6 is used for acquiring the image information of the tool when the machine tool works, the vibration sensor 2 is used for acquiring the vibration signal of the tool when the machine tool works, the output end of the vibration sensor 2 is connected with the input end of the signal processing circuit 3, the output of image acquisition module 6 is connected with the input of image processing module 7, the output of signal processing circuit 3, the output of temperature sensor 4, humidity transducer 5's output, the output of image processing module 7 and the output of power module 8 are connected with central processing unit 1's input respectively, the output of comparison module 9 is connected with alarm device 10's input, the input of comparison module 9, the input of display device 13 and the input of storage device 14 are connected with central processing unit 1's output respectively, central processing unit 1 is through wireless transmission device 11 and user's cell-phone 12 wireless communication connection.
In the above embodiment, the central processing unit 1, the vibration sensor 2, the signal processing circuit 3, the temperature sensor 4, the humidity sensor 5, the image acquisition module 6, the image processing module 7, the power supply module 8, the comparison module 9, the alarm device 10, the wireless transmission device 11, the user mobile phone 12, the display device 13 and the storage device 14 are utilized to realize effective monitoring of the tool of the numerical control machine tool during operation, not only can the vibration parameter of the tool during the processing process be tested through the vibration sensor 2 and compared with the preset vibration threshold value, but also the image information of the tool can be acquired through the image acquisition module 6, the worker can effectively monitor the tool of the numerical control machine tool by combining the tool vibration signal and the tool image information acquired by the vibration sensor 2 to avoid erroneous judgment, meanwhile, the influence of the environment on the tool during the machine tool operation is not negligible, therefore, the temperature and humidity of the environment during the operation of the machine tool can be detected by using the temperature sensor 4 and the humidity sensor 5, so that the working personnel can timely know the temperature and humidity information of the environment during the operation of the machine tool.
Specifically, the cpu 1 is an 8-bit microprocessor Atmega 128.
In the above embodiment, in consideration of the requirements of cost and processing performance, the central processing unit 1 selects the low-power-consumption 8-bit microprocessor Atmega128, the chip has rich hardware resources, and has the advantages of low power consumption, multiple functions, low price, strong performance and the like, the Atmega128 is provided with a 128K-byte Flash memory and a 4K-byte EEPROM memory, data acquired by the vibration sensor 2 is directly stored in the EEPROM memory, an ADC port inside the Atmega128 is provided with 8 channels, the resolution of each channel is 10 bits, the input voltage range is 0-5V, the requirement of monitoring data itinerant acquisition can be met, and an AD conversion device is not required to be additionally arranged, so that the design of a peripheral circuit is simplified, and the cost is reduced.
Specifically, the display device 13 is an LCD display unit, wherein the LCD display unit is a 20pinLCD1286 HZ.
In the above embodiment, the LCD display unit is powered by 3.3V voltage to be level-matched with the I/O port of the microprocessor Atmega128, and the interface between the LCD display unit and the microprocessor Atmega128 is communicated by a serial interface.
Specifically, the wireless transmission device 11 is a WiFi module, and the WiFi module is a VT6656 module.
In the above embodiment, the wireless transmission device 11 is a WiFi module, WiFi is a wireless networking technology, and the main advantage is that it does not need wiring and is not limited by wiring conditions, so it is particularly suitable for the needs of mobile office users, the WiFi module uses VT6656 module to implement remote transmission of data, the VT6656 module embeds TCP/IP protocol line, which reduces the difficulty of design, and greatly improves the capability of Atmega128 to process other data, the VT6656 is very simple to connect with Atmega128, and the two can be directly connected through standard USB interface, the VT6656 module uses 802.11g wireless ethernet access of 54Mbps standard, 5 times faster than 802.11b protocol, 40 times faster using USB2.0 interface than USB1.0 interface, new antenna technology supports wireless access of longer distance, 821.11g and 802.11b wireless router and access point supporting all standards, supports 64/128/256 bits WEP encryption, and advanced encryption and security mechanisms such as WPA/WPA2, WPA-PSK/WPA2-PSK and the like are supported.
As a further priority, as shown in fig. 2, the vibration sensor 2 is configured to collect vibration signals of a tool during operation of the machine tool, convert the collected vibration signals into voltage signals V0, and transmit the voltage signals V0 to the signal processing circuit 3, V1 is the voltage signals processed by the signal processing circuit 3, the signal processing circuit 3 includes a signal amplifying unit and a signal filtering unit, an output end of the vibration sensor 2 is connected to an input end of the signal amplifying unit, an output end of the signal amplifying unit is connected to an input end of the signal filtering unit, and an output end of the signal filtering unit is connected to an ADC port of the central processing unit 1.
Specifically, the signal amplification unit comprises integrated operational amplifiers A1-A3 and resistors R1-R14.
Wherein, the output end of the vibration sensor 2 is connected with one end of a resistor R1, the other end of the resistor R1 is connected with one end of a resistor R2, the other end of a resistor R1 is further connected with one end of a resistor R3, the other end of the resistor R3 is grounded, the other end of a resistor R2 is connected with one end of a resistor R4, the other end of a resistor R4 is grounded, the other end of a resistor R2 is further connected with the non-inverting input end of an integrated operational amplifier a1, one end of a resistor R5 is grounded, the other end of a resistor R5 is connected with one end of a resistor R6, the other end of a resistor R6 is connected with the inverting input end of an integrated operational amplifier a1, the other end of a resistor R5 is further connected with one end of a resistor R7, the output end of an integrated operational amplifier a1 is connected with one end of a resistor R10, the other end of a resistor R10 is grounded, the output end of an integrated operational amplifier a1 is further connected with the non-inverting input end of an integrated operational, the other end of the resistor R8 is further connected with one end of the resistor R9, the other end of the resistor R7 is connected with the other end of the resistor R9 in parallel and then connected with the output end of the integrated operational amplifier A2, the output end of the integrated operational amplifier A2 is further connected with one end of the resistor R11, the other end of the resistor R11 is grounded, the output end of the integrated operational amplifier A2 is further connected with one end of the resistor R12, the other end of the resistor R12 is connected with the non-inverting input end of the integrated operational amplifier A3, one end of the resistor R14 is connected with the inverting input end of the integrated operational amplifier A3, the other end of the resistor R14 is connected with the output end of the integrated operational amplifier A3, one end of the resistor R14 is further connected with one end of the resistor.
Specifically, the signal filtering unit comprises resistors R15-R21, capacitors C1-C2 and an integrated operational amplifier A4-A6.
Wherein, the output end of the signal amplifying unit is connected with one end of a resistor R15, the other end of a resistor R15 is connected with one end of a resistor R17 in parallel and then connected with the non-inverting input end of an integrated operational amplifier A4, the other end of a resistor R17 is connected with the output end of an integrated operational amplifier A4, one end of a resistor R16 is grounded, the other end of a resistor R16 is connected with a resistor R21 in parallel and then connected with the non-inverting input end of an integrated operational amplifier A4, the other end of a resistor R21 is connected with the output end of an integrated operational amplifier A5, the other end of a resistor R17 is connected with the output end of an integrated operational amplifier A4 in parallel and then connected with one end of a resistor R18, the other end of a resistor R18 is connected with one end of a capacitor C1 in parallel and then connected with the inverting input end of an integrated operational amplifier A5, the other end of a capacitor C1 is connected with the output end of an integrated operational amplifier A5 in parallel and then connected with one end of a resistor R19, the non-, the non-inverting input end of the integrated operational amplifier A6 is grounded, the other end of the capacitor C2 is connected with the output end of the integrated operational amplifier A6, one end of the resistor R20 is connected with the inverting input end of the integrated operational amplifier A4, the other end of the resistor R20 is connected with the output end of the integrated operational amplifier A6, one end of the resistor R21 is connected with the non-inverting input end of the integrated operational amplifier A4, the other end of the resistor R21 is connected with the output end of the integrated operational amplifier A5, the output end of the integrated operational amplifier A6 is connected with the ADC port of the central processing unit 1, and the signal processing unit transmits the processed voltage signal V1 to the ADC port of the central processing unit 1.
In the above embodiment, the noise of the signal processing circuit 3 is within 40nV, the drift is 0.5 μ V/° c, the integrated operational amplifier a1 is an LT1010 low-drift amplifier, the integrated operational amplifier a2 is an LT1012 high-speed amplifier, and the integrated operational amplifiers A3, a4, a5 and a6 are LT1097 operational amplifiers, and since the dc offset and the drift of the integrated operational amplifier a1 do not affect the overall offset of the circuit, the circuit has extremely low offset and drift.
The resistance value of the resistor R1 is 75 Ω, the resistance value of the resistor R2 is 1.5KΩ, the resistance value of the resistor R3 is 75 Ω, the resistance value of the resistor R4 is 75 Ω, the resistance value of the resistor R5 is 75 Ω, the resistance value of the resistor R6 is 300 Ω, the resistance value of the resistor R7 is 3.4KΩ, the resistance value of the resistor R8 is 250 Ω, the resistance value of the resistor R9 is 750 Ω, the resistance value of the resistor R10 is 1 Ω, the resistance value of the resistor R11 is 1KΩ, the resistance value of the resistor R12 is 1KΩ, the resistance value of the resistor R13 is 750 Ω, the resistance value of the resistor R14 is 750 Ω, the resistance value of the resistor R15 is 1.7KΩ, the resistance value of the resistor R16 is 4.7KΩ, the resistance value of the resistor R17 is 10KΩ, the resistance value of the resistor R18 is 5KΩ, the resistance value of the resistor R19 is 1 K6324, the capacitance value of the resistor R599 is 220pF C, and the capacitance value of the capacitor Pc3 pFC is 3C.
Because the signals collected by the vibration sensor 2 are weak voltage signals, the signal amplification unit amplifies the voltage V0 output by the vibration sensor 2 through the resistors R1-R14 and the integrated operational amplifiers A1-A3, wherein the signal amplification unit performs low-pass filtering on the amplified voltage signals through the resistors R15-R21, the capacitors C1-C2 and the integrated operational amplifiers A4-A6, so that the accuracy of tool vibration detection during operation of the machine tool is improved.
As a further priority of the above, as shown in fig. 3, the image processing module 7 includes an image denoising unit, an image enhancement unit, an image sharpening unit, and an image smoothing unit;
the image acquisition module 6 is used for acquiring image information of a cutter of a machine tool during operation, the output end of the image acquisition module 6 is connected with the input end of the image noise reduction unit, the output end of the image noise reduction unit is connected with the input end of the image enhancement unit, the output end of the image enhancement unit is connected with the input end of the image sharpening unit, the output end of the image sharpening unit is connected with the input end of the image smoothing unit, and the output end of the image smoothing unit is connected with the input end of the central processing unit 1.
In the above embodiment, the image processing module 7 sequentially performs image enhancement, image smoothing, image sharpening, and image grayscale conversion on the acquired image, so as to efficiently and quickly extract the image information of the image acquisition module 6, improve the accuracy of identifying the tool image, and effectively reduce the occurrence of erroneous judgment.
Specifically, the image acquisition module 6 is used for acquiring image information of a tool of the machine tool during operation, the vibration sensor 2 is used for acquiring a vibration signal of the tool of the machine tool during operation, the temperature sensor 4 is used for acquiring an ambient temperature signal of the machine tool during operation, and the humidity sensor 5 is used for acquiring an ambient humidity signal of the machine tool during operation.
Wherein, the vibration sensor 2 transmits the collected vibration signal of the tool during the operation of the machine tool to the signal processing circuit 3, the signal processing circuit 3 sequentially amplifies and filters the received vibration signal, the processed vibration signal is transmitted to an ADC port of the central processing unit 1, the central processing unit 1 transmits the received vibration signal to a display device 13 for display, the central processing unit 1 transmits the received vibration signal to a storage device 14 for storage, the central processing unit 1 transmits the received vibration signal to a user mobile phone 12 through a wireless transmission device 11, the central processing unit 1 transmits the received vibration signal to a comparison module 9, the comparison module 9 compares the received vibration signal with a preset vibration threshold value, and if the vibration signal received by the comparison module 9 is larger than the preset vibration threshold value, the alarm device 10 sends alarm information.
The image acquisition module 6 transmits acquired image information of a cutter of the machine tool during operation to the image processing module 7, the image processing module 7 performs image processing on the received image information and transmits the processed image information to the central processing unit 1, the central processing unit 1 transmits the received image information to the display device 13 for display, the central processing unit 1 transmits the received image information to the storage device 14 for storage, and the central processing unit 1 transmits the received image information to the user mobile phone 12 through the wireless transmission device 11; the temperature sensor 4 is used for acquiring an ambient temperature signal of the machine tool during operation, the temperature sensor 4 transmits the acquired ambient temperature signal of the machine tool during operation to the central processing unit 1, the central processing unit 1 transmits the received ambient temperature signal of the machine tool during operation to the display device 13 for display, the central processing unit 1 transmits the received ambient temperature signal of the machine tool during operation to the storage device 14 for storage, and the central processing unit 1 transmits the received ambient temperature signal of the machine tool during operation to the user mobile phone 12 through the wireless transmission device 11; humidity transducer 5 is used for gathering the environment humidity signal of lathe when the operation, humidity transducer 5 transmits the environment humidity signal of lathe when the operation of gathering to central processing unit 1, central processing unit 1 shows the environment humidity signal transmission of lathe when the operation of receiving to display device 13, central processing unit 1 stores the environment humidity signal transmission of lathe when the operation of receiving to storage device 14, central processing unit 1 transmits the environment humidity signal of lathe when the operation of receiving to user's cell-phone 12 through wireless transmission device 11.
In the above embodiment, the worker knows the ambient temperature information of the machine tool during operation through the display device 13 or the user mobile phone 12 carried with him/her, if it is found that the temperature and humidity are not suitable for the operation of the machine tool, the worker controls the machine tool to operate after performing temperature and humidity adjustment on the machine tool in the operation environment, and after receiving the alarm information of the alarm device 10, the worker can know the image information of the current tool through the display device 13 or the user mobile phone 12 carried with him/her to further determine whether the tool is abnormal/faulty, for example, whether the tool is faulty, such as loose, or the like, through the image information. That is, when the worker receives the alarm information of the alarm device 10, the worker determines that the current tool may have a fault, and then obtains the image information of the current tool through the display device 13 or the user mobile phone 12 carried with the worker to further confirm whether the tool has a fault.
Specifically, the image of the tool during operation of the machine tool, which is transmitted from the image acquisition module 6 to the image processing module 7, is defined as a two-dimensional function f (x, y), where x and y are space coordinates, the image denoising unit performs image denoising on the image f (x, y), and the two-dimensional function of the image after the image denoising is g (x, y), where g (x, y) is the two-dimensional function of the image after the image denoising processing
Specifically, the image enhancement unit performs image definition enhancement processing on an image g (x, y), and the two-dimensional function of the image after the image definition enhancement processing is h (x, y), wherein,
in the above embodiment, the purpose of the image noise reduction unit and the image enhancement unit is to improve the quality of the image acquired by the image acquisition module 12, remove noise in the image, make the edge clear, and improve the interpretability of the image
Specifically, the image sharpening unit performs image sharpening on the image h (x, y), and the two-dimensional function of the image after the image sharpening is d (x, y), wherein,
in the above embodiment, the image sharpening unit compensates the contour of the image after the image enhancement processing, and enhances the edge and the gradation transition portion of the image, so that the image becomes clearer.
Specifically, the image smoothing unit performs image smoothing processing on an image d (x, y), the two-dimensional function of the image after the image smoothing processing is s (x, y), the smoothing function is q (x, y),
where ﹡ is a convolution symbol,
for self-defining adjustable constants, smoothing is effected by
To be controlled.
In the above embodiment, the image smoothing unit gradually changes the brightness of the image subjected to the image sharpening process, and reduces the abrupt change gradient, thereby improving the image quality.
The image smoothing unit transmits the image s (x, y) to the central processor 1.
Preferably, the power module 8 provides power support for the central processing unit 1, the vibration sensor 2, the signal processing circuit 3, the temperature sensor 4, the humidity sensor 5, the image acquisition module 6, the image processing module 7, the comparison module 9, the alarm device 10, the wireless transmission device 11, the user mobile phone 12, the display device 13 and the storage device 14.
Preferably, the image capturing module 6 is a CCD image sensor, and the vibration sensor 2 is a compression-type acceleration sensor for testing.
The invention provides a machine tool cutter fault testing system which is an intelligent cutter fault diagnosis system, a central processing unit 1 is adopted to control the system, the intelligent degree is high, a vibration sensor 2 and an image acquisition module 6 are arranged, all aspects of information of a numerical control machine tool cutter can be monitored in time, the functions are comprehensive, the monitored information can be accurately analyzed, monitoring data can be fed back to a user mobile phone 12 in time through a wireless transmission device 11, a display device 13 and a storage device 14 are arranged, vibration data of the numerical control machine tool cutter and image information of the numerical control machine tool cutter can be displayed in real time, the vibration data of the numerical control machine tool cutter and the image information of the numerical control machine tool cutter can be stored, and a user can conveniently perform later analysis and research.
Finally, it should be noted that the above embodiments are only used for illustrating the technical solutions of the present invention and are not limited. Although the present invention has been described in detail with reference to the embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (10)
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