CN117359393A - Multi-signal cutter abrasion monitoring and controlling system in numerical control machining process - Google Patents

Abstract

The invention relates to the technical field of numerical control machine tools and discloses a multi-signal tool wear monitoring and controlling system in a numerical control machining process. The multi-signal cutter abrasion monitoring and controlling system in the numerical control machining process utilizes a plurality of groups of sensors to monitor cutting force, cutter temperature and cutter vibration frequency of cutters simultaneously, analyzes and processes data according to related algorithms, judges that the cutters reach abrasion early warning values when more than two groups of abnormal values occur, reminds operators to replace the cutters in time, and accordingly avoids the problems that single sensors are insufficient in sensitivity, accumulated in error and easy to be affected by environment, and the accuracy of monitoring results is affected, so that the accuracy of the monitoring results is improved.

Description

Multi-signal tool wear monitoring and control system for CNC machining process

Technical field

The invention relates to the technical field of CNC machine tools, specifically a multi-signal tool wear monitoring and control system in CNC machining processes.

Background technique

CNC machine tool is the abbreviation of Computer numerical control machine tools. It is an automated machine tool equipped with a program control system. The control system can logically process programs with control codes or other symbolic instructions, decode them, express them with coded numbers, and input them into the numerical control device through the information carrier. After calculation and processing, the CNC device sends out various control signals to control the movement of the machine tool, and automatically processes the parts according to the shape and size required by the drawing. CNC machine tools can better solve the problem of complex, precise, small batch, and multi-variety parts. Processing problem is a flexible, high-performance automated machine tool, which represents the development direction of modern machine tool control technology and is a typical electromechanical integration product.

Tool wear monitoring is particularly important during the machining process of CNC machine tools. During the machining process, it will gradually wear due to friction and heat generation. Severely worn tools may lead to problems such as reduced processing quality and workpiece damage. By monitoring multi-signal tool wear, Monitoring can provide real-time understanding of tool wear and take timely measures, such as tool replacement or tool sharpening, to ensure processing quality and workpiece integrity.

There are currently some shortcomings in multi-signal tool wear monitoring and control systems, such as sensor accuracy: The accuracy of the sensor is crucial to the effectiveness of wear monitoring. However, some sensors may have insufficient sensitivity, accumulation of errors, or are susceptible to environmental interference, affecting the accuracy of monitoring results.

Contents of the invention

(1) Technical problems solved

In view of the shortcomings of the existing technology, the present invention provides a multi-signal tool wear monitoring and control system in the CNC machining process, which is capable of using multiple sets of sensors to simultaneously monitor the cutting force, tool temperature and tool vibration frequency of the tool, and based on relevant algorithms, The data is analyzed and processed. When there are more than two sets of abnormal values, it is determined that the tool has reached the wear warning value and the operator is reminded to replace the tool in time, thereby avoiding the problems of insufficient sensitivity, error accumulation and susceptibility to environmental interference of a single sensor, resulting in monitoring The accuracy of the results is affected, thereby improving the accuracy of the monitoring results and other advantages, solving the above problems.

(2) Technical solutions

In order to achieve the above objects, the present invention provides the following technical solution: a multi-signal tool wear monitoring and control system for CNC machining processes, which is characterized by: including an acquisition module, a data processing module and an early warning control module. The acquisition module and the data processing module Network connection, the data processing module is network connected with the early warning control module;

The acquisition module includes a force sensor, a vibration sensor and a temperature sensor, where:

The force sensor is used to collect the cutting force Qxl data of the machine tool tool, the vibration sensor is used to collect the vibration frequency Zd data of the machine tool tool during the machining process, and the temperature sensor is used to collect the tool surface temperature of the machine tool tool during the machining process. Wd data, the acquisition module sends the collected cutting force Qxl data, vibration frequency Zd data and tool surface temperature Wd data to the data processing module;

The data processing module divides the multiple cutting force Qxl data into one group every 10 seconds, and calculates the average cutting force Qxl _pj . The initial cutting force Qxl _cs of the tool is preset in the data processing module. The data processing module The module brings the current cutting force average Qxl _pj into the algorithm formula to calculate the cutting force deviation rate Qxl _pc . The cutting force deviation threshold Qxl _yz is preset in the data processing module. The data processing module converts the cutting force deviation rate Qxl _pc into Compare with the cutting force deviation threshold Qxl _yz to determine the tool wear and send the data to the early warning control module;

The data processing module divides multiple vibration frequency Zd data into one group every 5 seconds, and calculates the average vibration frequency Zd _pj . The initial vibration value of the tool Zd _cs is preset in the data processing module. The data processing module The average vibration frequency Zd _pj and the initial vibration value Zd _cs of the tool are brought into the algorithm formula to calculate the tool wear index MS. The tool wear index threshold MS _yz is preset in the data processing module. The data processing module combines the tool wear index MS with Compare the tool wear index threshold MS _yz to determine the tool wear condition and send the data to the early warning control module;

The tool surface temperature Wd data is collected every 10 seconds. The data processing module labels the collected tool surface temperature Wd data according to the time sequence, for example: Wd _q and Wd _h . The data processing module labels the collected tool surface temperature Wd data according to Wd _q. and Wd _h to numerically calculate the tool temperature change rate Wd _bh . A temperature change rate threshold Wd _yz is preset in the data processing module. The data processing module compares the tool temperature change rate Wd _bh with the temperature change rate threshold Wd _yz to determine Tool wear status and send the data to the early warning control module;

The early warning control module determines the tool wear status based on the received three sets of tool wear data, and issues an early warning or controls the machine tool to shut down.

Preferably, the calculation formula of the average cutting force Qx _pj is as follows:

In the formula, Qxl _n-9 , Qxl _n-8 , Qxl _n-7 ,..., Qxl _n represent the cutting force Qxl value within 10 seconds, 10 means 10 seconds, and the average cutting force Qxl _pj for 10 seconds is obtained. .

Preferably, the cutting force deviation rate Qxl _pc is calculated as follows:

After the data processing module obtains the cutting force deviation rate Qxl _pc , it compares the cutting force deviation rate Qxl _pc with the cutting force deviation threshold Qxl _yz , and sends the comparison result to the early warning control module.

Preferably, the calculation formula for the average vibration frequency Zd _pj is as follows:

In the formula, Zd _n-4 , Zd _n-3 ,..., Zd _n represent five consecutive vibration frequency Zd data values within five seconds, 5 represents 5 seconds, and the average vibration frequency within 5 seconds Zd _pj is obtained.

Preferably, the calculation formula of the tool wear index MS is as follows:

The data processing module compares the calculated tool wear index MS with the preset tool wear index threshold MS _yz , and sends the comparison result to the early warning control module.

Preferably, the tool temperature change rate Wd _bh is calculated as follows:

In the formula, Wd _h is the current tool temperature data value, Wd _q is the temperature data value of the previous 10 seconds of the current tool temperature data value, calculate the temperature difference between 10 seconds based on Wd _h -Wd _q , and divide it by the value collected in the previous 10 seconds. The data value Wd _q is obtained, and the tool temperature change rate Wd _bh is obtained.

Preferably, the data processing module compares the calculated tool temperature change rate Wd _bh with the preset temperature change rate threshold Wd _yz , and sends the comparison result to the early warning control module.

Preferably, the cutting force deviation threshold Qxl _yz is set according to the specific model and material of the tool, the tool wear index threshold MS _yz is set according to the specific model and material of the tool, and the temperature change rate threshold Wd _yz is set according to the specific model and material of the tool. .

Preferably, when the early warning control module receives three sets of tool wear data, when the cutting force deviation rate Qxl _pc is greater than the cutting force deviation threshold Qxl _yz or the tool wear index MS is greater than the preset tool wear index threshold MS _yz or the tool temperature changes When the rate Wd _bh is greater than the preset temperature change rate threshold Wd _yz , the early warning control module issues an alarm that the suspected tool reaches the early warning value.

Preferably, when the cutting force deviation rate Qxl _pc is greater than the cutting force deviation threshold Qxl _yz or the tool wear index MS is greater than the preset tool wear index threshold MS _yz or the tool temperature change rate Wd _bh is greater than the preset temperature change rate threshold Wd _yz , two situations occur. When any abnormal value is detected, the early warning control module determines that the tool has reached the early warning value, and the early warning control module starts an alarm and controls the machine tool to stop.

Compared with the existing technology, the present invention provides a multi-signal tool wear monitoring and control system for CNC machining processes, which has the following beneficial effects:

1. The present invention judges three sets of tool wear data through the early warning module. When the cutting force deviation rate Qxl _pc is greater than the cutting force deviation threshold Qxl _yz or the tool wear index MS is greater than the preset tool wear index threshold MS _yz or the tool temperature change rate Wd _bh is greater than the preset temperature change rate threshold Wd _yz . When any of the abnormal values occurs, the early warning control module issues an alarm that the tool is suspected of reaching the early warning value, reminding the operator that the tool is suspected of reaching the early warning value of the tool, and the tool needs to be stopped to check. , when the cutting force deviation rate Qxl _pc is greater than the cutting force deviation threshold Qxl _yz or the tool wear index MS is greater than the preset tool wear index threshold MS _yz or the tool temperature change rate Wd _bh is greater than the preset temperature change rate threshold Wd _yz , two groups of arbitrary When the value is abnormal, the early warning control module determines that the tool has reached the early warning value. The early warning control module starts an alarm and controls the machine tool to stop, thereby preventing the tool from continuing to work after exceeding the wear warning value and reducing the quality of part processing. Multiple sets of sensors are used to monitor the tool at the same time. The cutting force, tool temperature and tool vibration frequency are monitored, and the data is analyzed and processed according to relevant algorithms. When there are more than two sets of abnormal values, it is determined that the tool has reached the wear warning value, and the operator is reminded to replace the tool in time, thereby avoiding A single sensor has problems such as insufficient sensitivity, accumulation of errors, and susceptibility to environmental interference, which affects the accuracy of monitoring results, thereby improving the accuracy of monitoring results.

Description of the drawings

Figure 1 is a schematic flow diagram of the system of the present invention.

Detailed ways

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of the present invention.

Please refer to Figure 1, a multi-signal tool wear monitoring and control system in CNC machining process, including an acquisition module, a data processing module and an early warning control module. The acquisition module is network connected to the data processing module, and the data processing module is network connected to the early warning control module;

The acquisition module includes force sensors, vibration sensors and temperature sensors;

The force sensor is used to collect the cutting force Qxl data of the machine tool tool, the vibration sensor is used to collect the vibration frequency Zd data of the machine tool tool during the machining process, and the temperature sensor is used to collect the tool surface temperature Wd data of the machine tool tool during the machining process. The acquisition module will The collected cutting force Qxl data, vibration frequency Zd data and tool surface temperature Wd data are sent to the data processing module;

The data processing module divides multiple cutting force Qxl data into groups every 10 seconds, and calculates the average cutting force Qxl _pj . The calculation formula of the average cutting force Qxl _pj is as follows:

In the formula, Qxl _n-9 , Qxl _n-8 , Qxl _n-7 ,..., Qxl _n represent the cutting force Qxl value within 10 seconds, 10 means 10 seconds, and the average cutting force Qxl _pj for 10 seconds is obtained. , by calculating the average cutting force Qxl _pj , the accuracy of the numerical value is improved, and individual abnormal values lead to large deviations in subsequent calculation results and false triggering of early warning alarms;

The initial cutting force Qxl _cs of the tool is preset in the data processing module. The data processing module brings the average value of the current cutting force Qxl _pj into the algorithm formula to calculate the cutting force deviation rate Qxl _pc . The calculation formula of the cutting force deviation rate Qxl _pc is as follows:

The cutting force deviation threshold Qxl _yz is preset in the data processing module. After the data processing module obtains the cutting force deviation rate Qxl _pc , it compares the cutting force deviation rate Qxl _pc with the cutting force deviation threshold Qxl _yz , and sends the comparison result to the early warning In the control module;

The data processing module divides multiple vibration frequency Zd data into groups every 5 seconds, and calculates the average vibration frequency Zd _pj . The calculation formula for the average vibration frequency Zd _pj is as follows:

In the formula, Zd _n-4 , Zd _n-3 ,..., Zd _n represent five consecutive vibration frequency Zd data values within five seconds, 5 represents 5 seconds, and the average vibration frequency Zd _pj within 5 seconds is obtained. Calculate the mean value of vibration frequency Zd _pj to improve the accuracy of the value and avoid individual abnormal values causing large deviations in subsequent calculation results and triggering early warning alarms by mistake;

The initial vibration value Zd _cs of the tool is preset in the data processing module. The data processing module brings the average vibration frequency Zd _pj and the initial vibration value Zd _{cs of} the tool into the algorithm formula to calculate the tool wear index MS. The calculation formula of the tool wear index MS is as follows:

The tool wear index threshold MS _yz is preset in the data processing module. The data processing module compares the tool wear index MS with the tool wear index threshold MS _yz , and sends the comparison result to the early warning control module;

The tool surface temperature Wd data is collected every 10 seconds. The data processing module labels the collected tool surface temperature Wd data according to the time sequence, for example: Wd _q and Wd _h . The data processing module calculates the tool based on the values of Wd _q and Wd _h . Temperature change rate Wd _bh , tool temperature change rate Wd _bh is calculated as follows:

In the formula, Wd _h is the current tool temperature data value, Wd _q is the temperature data value of the previous 10 seconds of the current tool temperature data value, calculate the temperature difference between 10 seconds based on Wd _h -Wd _q , and divide it by the value collected in the previous 10 seconds. The data value Wd _q is obtained, and the tool temperature change rate Wd _bh is obtained. The temperature change rate threshold Wd _yz is preset in the data processing module. The data processing module combines the calculated tool temperature change rate Wd _bh with the preset temperature change rate. Compare the threshold Wd _yz and send the comparison result to the early warning control module;

And the cutting force deviation threshold Qxl _yz , tool wear index threshold MS _yz and temperature change rate threshold Wd _yz in this article are set according to the specific model and material of the tool;

When the early warning control module receives three sets of tool wear data, when the cutting force deviation rate Qxl _pc is greater than the cutting force deviation threshold Qxl _yz or the tool wear index MS is greater than the preset tool wear index threshold MS _yz or the tool temperature change rate Wd _bh is greater than the preset Set the temperature change rate threshold Wd _yz . When any of the abnormal values occurs, the early warning control module issues an alarm that the tool is suspected of reaching the early warning value, reminding the operator that the tool is suspected of reaching the early warning value of the tool, and the tool needs to be stopped for inspection. When cutting When the force deviation rate Qxl _pc is greater than the cutting force deviation threshold Qxl _yz or the tool wear index MS is greater than the preset tool wear index threshold MS _yz or the tool temperature change rate Wd _bh is greater than the preset temperature change rate threshold Wd _yz, two groups of any abnormal values occur , the early warning control module determines that the tool has reached the early warning value. The early warning control module starts an alarm and controls the machine tool to stop, thereby preventing the tool from continuing to work after exceeding the wear warning value and reducing the quality of part processing. Multiple sets of sensors are used to simultaneously monitor the cutting force and cutting force of the tool. The tool temperature and tool vibration frequency are monitored, and the data is analyzed and processed according to relevant algorithms to avoid the problems of insufficient sensitivity, error accumulation and susceptibility to environmental interference of a single sensor, which will affect the accuracy of the monitoring results, thereby improving ensure the accuracy of monitoring results.

Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art will understand that various changes, modifications, and substitutions can be made to these embodiments without departing from the principles and spirit of the invention. and modifications, the scope of the invention is defined by the appended claims and their equivalents.

Claims (10)

1. A multi-signal tool wear monitoring and control system in CNC machining process, characterized by: including an acquisition module, a data processing module and an early warning control module. The acquisition module is connected to the data processing module through a network, and the data processing module is connected to the early warning module. Control module network connection; The acquisition module includes a force sensor, a vibration sensor and a temperature sensor, where: The force sensor is used to collect the cutting force Qxl data of the machine tool tool, the vibration sensor is used to collect the vibration frequency Zd data of the machine tool tool during the machining process, and the temperature sensor is used to collect the tool surface temperature of the machine tool tool during the machining process. Wd data, the acquisition module sends the collected cutting force Qxl data, vibration frequency Zd data and tool surface temperature Wd data to the data processing module; The data processing module divides the multiple cutting force Qxl data into one group every 10 seconds, and calculates the average cutting force Qxl _pj . The initial cutting force Qxl _cs of the tool is preset in the data processing module. The data processing module The module brings the current cutting force average Qxl _pj into the algorithm formula to calculate the cutting force deviation rate Qxl _pc . The cutting force deviation threshold Qxl _yz is preset in the data processing module. The data processing module converts the cutting force deviation rate Qxl _pc into Compare with the cutting force deviation threshold Qxl _yz to determine the tool wear and send the data to the early warning control module; The data processing module divides multiple vibration frequency Zd data into one group every 5 seconds, and calculates the average vibration frequency Zd _pj . The initial vibration value of the tool Zd _cs is preset in the data processing module. The data processing module The average vibration frequency Zd _pj and the initial vibration value Zd _cs of the tool are brought into the algorithm formula to calculate the tool wear index MS. The tool wear index threshold MS _yz is preset in the data processing module. The data processing module combines the tool wear index MS with Compare the tool wear index threshold MS _yz to determine the tool wear condition and send the data to the early warning control module; The tool surface temperature Wd data is collected every 10 seconds. The data processing module labels the collected tool surface temperature Wd data according to the time sequence, for example: Wd _q and Wd _h . The data processing module labels the collected tool surface temperature Wd data according to Wd _q. and Wd _h to numerically calculate the tool temperature change rate Wd _bh . A temperature change rate threshold Wd _yz is preset in the data processing module. The data processing module compares the tool temperature change rate Wd _bh with the temperature change rate threshold Wd _yz to determine Tool wear status and send the data to the early warning control module; The early warning control module determines the tool wear status based on the received three sets of tool wear data, and issues an early warning or controls the machine tool to shut down. 2. The multi-signal tool wear monitoring and control system in CNC machining process according to claim 1, characterized in that: the calculation formula of the average cutting force Qxl _pj is as follows: In the formula, Qxj _n-9 , Qxl _n-8 , Qxl _n-7 ,..., Qxl _n represent the cutting force Qxl value within 10 seconds, 10 represents 10 seconds, and the average cutting force Qxl _pj for 10 seconds is obtained. . 3. The multi-signal tool wear monitoring and control system for CNC machining processes according to claim 2, characterized in that: the cutting force deviation rate Qxj _pc is calculated with the following formula: After the data processing module obtains the cutting force deviation rate Qxj _pc , it compares the cutting force deviation rate Qxl _pc with the cutting force deviation threshold Qxl _yz , and sends the comparison result to the early warning control module. 4. The multi-signal tool wear monitoring and control system in CNC machining process according to claim 1, characterized in that: the calculation formula of the vibration frequency mean value Zd _pj is as follows: In the formula, Zd _n-4 , Zd _n-3 ,..., Zd _n represent five consecutive vibration frequency Zd data values within five seconds, 5 represents 5 seconds, and the average vibration frequency within 5 seconds Zd _pj is obtained. 5. The multi-signal tool wear monitoring and control system in CNC machining process according to claim 4, characterized in that: the calculation formula of the tool wear index MS is as follows: The data processing module compares the calculated tool wear index MS with the preset tool wear index threshold MS _yz , and sends the comparison result to the early warning control module. 6. The multi-signal tool wear monitoring and control system in CNC machining process according to claim 1, characterized in that: the calculation formula of the tool temperature change rate Wd _bh is as follows: In the formula, Wd _h is the current tool temperature data value, Wd _q is the temperature data value of the previous 10 seconds of the current tool temperature data value, calculate the temperature difference between 10 seconds based on Wd _h -Wd _q , and divide it by the value collected in the previous 10 seconds. The data value Wd _q is obtained, and the tool temperature change rate Wd _bh is obtained. 7. The multi-signal tool wear monitoring and control system of CNC machining process according to claim 6, characterized in that: the data processing module combines the calculated tool temperature change rate Wd _bh with the preset temperature change rate threshold Wd _yz Compare and send the comparison results to the early warning control module. 8. The multi-signal tool wear monitoring and control system for CNC machining processes according to claim 3 or 5 or 7, characterized in that: the cutting force deviation threshold Qxl _yz is set according to the specific model and material of the tool, and the tool wear index The threshold value MS _yz is set according to the specific model and material of the tool, and the temperature change rate threshold Wd _yz is set according to the specific model and material of the tool. 9. The multi-signal tool wear monitoring and control system for CNC machining processes according to claim 3 or 5 or 7, characterized in that: when the early warning control module receives three sets of tool wear data, when the cutting force deviation rate Qxj _pc When the cutting force deviation threshold Qxl _yz is greater than the cutting force deviation threshold Qxl yz or the tool wear index MS is greater than the preset tool wear index threshold MS _yz or the tool temperature change rate Wd _bh is greater than the preset temperature change rate threshold Wd _yz , the early warning control module issues a suspected tool arrival warning value alert. 10. The multi-signal tool wear monitoring and control system for CNC machining processes according to claim 9, characterized in that: when the cutting force deviation rate Qxl _pc is greater than the cutting force deviation threshold Qxl _yz or the tool wear index MS is greater than the preset tool wear When the index threshold MS _yz or the tool temperature change rate Wd _bh is greater than the preset temperature change rate threshold Wd _yz and two groups of any abnormal values occur, the early warning control module determines that the tool has reached the early warning value, and the early warning control module starts the alarm and controls the machine tool stop.