CN118799724B - A CNC tool breakage monitoring and control method, system, storage medium and program product - Google Patents
A CNC tool breakage monitoring and control method, system, storage medium and program product Download PDFInfo
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Abstract
The invention discloses a CNC cutter breaking monitoring control method, a CNC cutter breaking monitoring control system, a storage medium and a program product, the system comprises an image acquisition module, an image processing module, a database, a cutter breakage prediction module, a data processing and communication module and a CNC control execution module. The invention realizes the monitoring functions of cutter temperature, cutter abrasion condition, cutter contact state with a workpiece, cutter working path, cutter moving speed and cutter acceleration, wherein in the monitoring of cutter abrasion condition, cutter breakage condition can be monitored very directly, when cutter breakage occurs, whether cutter breakage risk exists in the cutter can be analyzed by analyzing the temperature, abrasion condition, contact state with the workpiece, working path, moving speed and acceleration in the cutter working process, comprehensive prediction is carried out aiming at various factors of cutter breakage, cutter breakage occurrence probability is effectively reduced, the protection effect is achieved on CNC machine tools, cutters and workpieces, and meanwhile, a plurality of sensors of different types are not needed in hardware aspect.
Description
Technical Field
The invention belongs to the technical field of computer numerical control, relates to cutter monitoring control of a numerical control machine, and in particular relates to a CNC cutter breaking monitoring control method, a CNC cutter breaking monitoring control system, a CNC cutter breaking monitoring control storage medium and a CNC cutter breaking monitoring control program product.
Background
Numerical control machining (Computer Numerical Control, CNC) is a process for automated machining by a numerical control machine, which is mainly realized by automatically controlling movement of a cutter during machining, and machining a workpiece. In the numerical control machining process, the cutter is used as a key tool to be in direct contact with a workpiece and performs cutting operation, and phenomena such as high temperature and abrasion can be generated, so that the cutter has a fracture problem. Although the cutter fracture does not affect the operation of the power device of the numerical control machine tool, after the cutter fracture, the numerical control machine tool continuously works to damage the cutter and a workpiece, so that a cutter breakage monitoring system is required to monitor.
At present, the cutter breakage monitoring mode is to install a plurality of sensors in CNC for monitoring, each sensor needs to work independently, the working state of the cutter is judged by collecting corresponding physical quantity, the monitoring effect of the cutter in the working process is poor, and the defects that firstly, a multi-sensor system is complex and high in cost, and each sensor needs an independent signal collecting and processing device are overcome, so that the complexity and cost of the system are increased, and the difficulty of data processing and analysis is also caused. Secondly, the existing broken cutter monitoring system cannot predict the broken cutter and analyze the broken cutter factors, and most systems only can give an alarm after the cutter breaks, cannot give an early warning before the cutter breaks, and cannot reduce the cutter breaking condition. In addition, the system does not provide detailed analysis of the cause of the knife break, and is also inconvenient for the staff to conduct targeted maintenance and improvement.
In summary, the current cutter breakage monitoring technology in the numerical control machining process still has a number of technical problems to be solved. The problems include high system complexity, difficulty in realizing cutter breakage prediction and cutter breakage factor analysis, incapability of providing early warning before cutter breakage, incapability of reducing cutter breakage conditions, inconvenience for staff to analyze cutter breakage factors and the like, and how to design a cutter breakage monitoring system which is efficient, reliable and easy to maintain so as to improve monitoring precision and reliability, realize effective early warning before cutter breakage, provide detailed cutter breakage cause analysis and solve the problems to be solved urgently.
Disclosure of Invention
Object of the invention
The invention aims to provide a CNC cutter breaking monitoring control method, a CNC cutter breaking monitoring control system, a CNC cutter breaking monitoring control storage medium and a CNC cutter breaking monitoring control program product, and the problems that cutter temperature, abrasion condition, contact state with a workpiece, working path, moving speed and acceleration are comprehensively monitored, cutter breaking prediction and cutter breaking factor analysis cannot be achieved in the prior art, early warning cannot be provided before cutter breaking, cutter breaking condition cannot be reduced, and meanwhile, analysis aiming at cutter breaking factors by workers is inconvenient are solved.
(II) technical scheme
In order to achieve the aim of the invention and solve the technical problems, the invention adopts the following technical scheme:
the 1 st object of the present invention is to provide a CNC cutter-breaking monitoring control method, which at least includes the following implementation steps when executed:
the method comprises the steps of SS1, continuously shooting the working state of a cutter on the inner side of a CNC machine tool based on an image acquisition module installed in the CNC machine tool or arranged on a tool apron of the CNC machine tool, and acquiring working video data of the cutter;
SS2, extracting a shot image in the cutter working video data, and processing the extracted shot image, wherein the image processing at least comprises enhancement, edge processing and feature extraction;
SS3, constructing a database, and pre-storing related data of a standard tool working state, wherein the related data comprises image characteristic data, wear grade data, a mapping relation model of image characteristics and tool temperature, and standard ranges and thresholds of tool temperature, tool-workpiece contact state, tool working path, tool moving speed and acceleration under different working states, and the image characteristic data at least comprises color characteristics, texture characteristics and shape characteristics corresponding to different tool wear grades;
SS4, comparing and analyzing based on the image characteristic data extracted after the image processing in the step SS2 and combining with the standard cutter related data pre-stored in a database, and comprehensively judging whether the cutter has fracture risk;
And SS5, classifying and processing the cutter fracture risk analysis result, generating a control instruction based on the cutter fracture risk analysis result, and performing operations of stopping, alarming or adjusting the machining process parameters.
It is an object of invention 2 to provide a computer program product comprising computer instructions for instructing a computing device for performing the above-mentioned CNC cutter breakage monitoring control method of the present invention.
A3 rd aspect of the present invention is to provide a computer-readable storage medium having a computer program stored thereon, which when executed by a processor, implements the CNC cutter breakage monitoring control method of the present invention.
The 4 th invention of the invention aims at a CNC cutter breaking monitoring control system which is used for monitoring the working state of a cutter in the numerical control machining process in real time and analyzing and predicting the risk of cutter breakage, and comprises an image acquisition module, an image processing module, a database, a cutter breaking prediction module, a data processing and communication module and a CNC control execution module, and is characterized in that,
The image acquisition module is arranged in the CNC machine tool or on a tool apron of the CNC machine tool, and is used for continuously shooting the working state of the tool inside the CNC machine tool, acquiring working video data of the tool, and transmitting the acquired video data to the downstream image processing module;
The input end of the image processing module is connected with the image acquisition module and is used for receiving the cutter working video data, extracting a shot image in the video, processing the extracted shot image, wherein the image processing at least comprises enhancement, edge processing and feature extraction, and transmitting the processed image feature data to a downstream cutter breaking prediction module;
The method comprises the steps that data related to a standard cutter working state are prestored in a database, wherein the data comprise image characteristic data, wear grade data, a mapping relation model of image characteristics and cutter temperature, and standard ranges and thresholds of cutter temperature, cutter contact state with a workpiece, cutter working path, cutter moving speed and acceleration under different working states, and the image characteristic data at least comprise color characteristics, texture characteristics and shape characteristics corresponding to different cutter wear grades;
the input end of the cutter breakage prediction module is in communication connection with the image processing module and the database, and is used for carrying out comparison and analysis based on the image characteristic data extracted by the image processing module and in combination with the standard cutter related data prestored in the database, comprehensively judging whether a cutter has a breakage precursor or not, and outputting a judging result to a downstream data processing and communication module;
The input end of the data processing and communication module is in communication connection with the cutter breaking prediction module and is used for receiving and classifying the analysis result of the cutter breaking prediction module and transmitting the result to the CNC control execution module;
The input end of the CNC control execution module is in communication connection with the data processing and communication module and is used for generating a control instruction according to the analysis result and performing operations of stopping, alarming or adjusting the processing technological parameters based on the control instruction.
(III) technical effects
Compared with the prior art, the CNC cutter breaking monitoring control method, the CNC cutter breaking monitoring control system, the storage medium and the program product have the following beneficial and remarkable technical effects:
(1) According to the invention, a mode of image processing after shooting is adopted, so that the monitoring functions of cutter temperature, cutter abrasion condition, cutter contact state with a workpiece, cutter working path, cutter moving speed and cutter acceleration are realized, wherein in the monitoring of cutter abrasion condition, the cutter breakage condition can be directly monitored, when the cutter breakage occurs, a command can be timely output to a CNC control system, meanwhile, whether the cutter breakage risk exists in the cutter can be analyzed by analyzing the temperature, abrasion condition, contact state with the workpiece, working path, moving speed and acceleration in the cutter working process, the comprehensive prediction is carried out on various factors of cutter breakage, the cutter breakage occurrence probability is effectively reduced, the protection effect is realized on CNC machine tools, cutters and workpieces, a plurality of sensors of different types are not needed in hardware aspect, the use cost and maintenance cost/difficulty are reduced, and meanwhile, the cutter breakage monitoring precision is also improved;
(2) According to the invention, the tool setting monitoring module is added by utilizing image processing, so that tool setting monitoring can be performed in real time, and the condition of tool breakage caused by calibration of the tool is reduced. In addition, in the invention, the cutter breaking analysis module collects and classifies various processed cutter breaking prediction conditions, and when cutter breaking occurs, cutter breaking factor data with cutter temperature, cutter abrasion condition, cutter and workpiece contact state, cutter working path, cutter moving speed and cutter acceleration are generated, so that a worker can conveniently carry out adaptability improvement on CNC (computerized numerical control) machine tools and cutters according to cutter breaking factors, meanwhile, the image processing module comprises a video recording unit and can record videos when cutter breaking occurs, and the image processing module can be pushed forward for 5-10min, so that professionals can conveniently judge cutter breaking factors through slowly releasing the whole videos, and convenience is brought to carrying out improvement work of cutters or CNC (computerized numerical control) machine tools.
Drawings
Fig. 1 is a flowchart of a CNC knife break monitoring control method of the present invention.
Fig. 2 is a schematic block diagram of a CNC knife break monitoring control system of the present invention.
Detailed Description
For a better understanding of the present invention, the following examples are set forth to illustrate the present invention. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are some, but not all, embodiments of the invention. The embodiments described below by referring to the drawings are illustrative and intended to explain the present invention and should not be construed as limiting the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention. The following describes the structure and technical scheme of the present invention in detail with reference to the accompanying drawings, and an embodiment of the present invention is given.
Example 1
The invention aims to solve the problems that in the prior art, the cutter breaking prediction and the cutter breaking factor analysis cannot be realized, the early warning cannot be provided before the cutter breaking, the cutter breaking condition cannot be reduced, and meanwhile, the analysis of the cutter breaking factor by a worker is inconvenient. As a specific example, as shown in fig. 1, the CNC cutter-breaking monitoring control method provided by the present invention mainly includes the following implementation steps when executing:
the method comprises the steps of SS1, continuously shooting the working state of a cutter on the inner side of a CNC machine tool based on an image acquisition module installed in the CNC machine tool or arranged on a tool apron of the CNC machine tool, and acquiring working video data of the cutter;
SS2, extracting a shot image in the cutter working video data, and processing the extracted shot image, wherein the image processing at least comprises enhancement, edge processing and feature extraction;
SS3, constructing a database, and pre-storing related data of a standard tool working state, wherein the related data comprises image characteristic data, wear grade data, a mapping relation model of image characteristics and tool temperature, and standard ranges and thresholds of tool temperature, tool-workpiece contact state, tool working path, tool moving speed and acceleration under different working states, and the image characteristic data at least comprises color characteristics, texture characteristics and shape characteristics corresponding to different tool wear grades;
SS4, comparing and analyzing based on the image characteristic data extracted after the image processing in the step SS2 and combining with the standard cutter related data pre-stored in a database, and comprehensively judging whether the cutter has fracture risk;
And SS5, classifying and processing the cutter fracture risk analysis result, generating a control instruction based on the cutter fracture risk analysis result, and performing operations of stopping, alarming or adjusting the machining process parameters.
Through the implementation steps, the CNC cutter breakage monitoring control method provided by the invention can realize real-time monitoring of the working state of the cutter and prediction of the breakage risk. According to the method, the processing process video is acquired in real time, the acquired image is processed and analyzed based on standard data stored in the database, real-time monitoring of the cutter state is achieved, and the fracture risk is analyzed and predicted, so that early warning or automatic adjustment of processing parameters can be sent out to a CNC system before cutter breakage, the problems that cutter breakage prediction is insufficient, cutter breakage factor analysis is incomplete and the like in the prior art are effectively solved, safety and efficiency of the CNC processing process are improved, targeted analysis and optimization processing by workers are facilitated, and cutter breakage accidents are reduced.
Example 2
Corresponding to the above embodiment 1, as shown in fig. 2, the present invention further provides a CNC cutter breakage monitoring control system, which includes an image acquisition module (preferably an industrial camera), an image processing module, a database, a cutter breakage prediction module, a data processing and communication module, and a CNC control execution module, wherein the industrial camera of the image acquisition module is installed in a CNC machine or disposed on a cutter holder of the CNC machine, and is configured to continuously shoot a working state of a cutter inside the CNC machine, obtain working video data of the cutter, and transmit the obtained video data to a downstream image processing module, and an input end of the image processing module in communication is connected to the industrial camera of the image acquisition module, and is configured to receive the working video data of the cutter and extract a shot image in the video, and at the same time process the extracted shot image, where the image processing at least includes enhancement, edge processing, and feature extraction, and transmit the processed image feature data to the downstream cutter breakage prediction module.
Meanwhile, the database is used for pre-storing related data of the working state of the standard tool, and comprises image characteristic data, wear grade data, a mapping relation model of image characteristics and tool temperature, and standard ranges and thresholds of the tool temperature, the tool contact state with a workpiece, the tool working path, the tool moving speed and the acceleration under different working states, wherein the image characteristic data at least comprises color characteristics, texture characteristics and shape characteristics corresponding to different tool wear grades.
In addition, the input end of the cutter breakage prediction module is in communication connection with the image processing module and the database, is used for comparing based on image characteristic data extracted by the image processing module and combined with standard cutter related data prestored in the database, comprehensively analyzes and judges whether a cutter has a breakage precursor based on cutter temperature, cutter abrasion degree, cutter contact state with a workpiece, cutter working path, cutter moving speed and cutter acceleration in the current working state, and outputs a judging result to a downstream data processing and communication module, wherein the input end of the data processing and communication module is in communication connection with the cutter breakage prediction module and is used for receiving the analyzing result of the cutter breakage prediction module, classifying and transmitting the result to the CNC control system, and the input end of the CNC control system is in communication connection with the data processing and communication module and is used for making corresponding operations including but not limited to shutdown, alarm or adjustment of processing technological parameters according to the analyzing result.
In the preferred embodiment of the invention, the cutter breakage prediction module comprises cutter temperature prediction, wherein the cutter temperature prediction specific operation process comprises the steps that an industrial camera shoots cutter images in real time in the cutter working process, the images are processed by an image processing module to obtain current brightness characteristics, color characteristics and texture characteristics of the cutter, the current brightness characteristics, the color characteristics and the texture characteristics of the cutter are compared with the brightness characteristics, the color characteristics and the texture characteristics of the cutter pre-stored in a database, the cutter temperature under the characteristics is obtained based on a mapping relation model of the image characteristics and the cutter temperature pre-stored in the database, when the temperature reaches a cutter temperature threshold range set in the database, the cutter breakage risk is represented, the data processing and communication module sends a signal to a CNC control system, the CNC control system executes stopping, alarming or other operations of the cutter, the service life of the cutter is directly influenced by the cutter temperature, and meanwhile if the temperature is too high in the cutter working process, the cutter breakage risk is brought to the cutter, so that the cutter temperature is timely obtained, and compared with the cutter temperature threshold, the cutter breakage risk can be effectively predicted according to the cutter working temperature, and the cutter breakage probability is reduced.
In a further preferred example, the construction of the mapping relation model of the image features and the cutter temperatures comprises the steps of collecting image data in the working process of the cutter, extracting brightness features, color features and texture features of the image data, recording the actual cutter temperatures corresponding to each feature, storing the actual cutter temperatures in a database, setting a cutter temperature threshold range in the database, establishing a mapping relation model between the cutter temperatures and the image features by using a linear regression statistical learning method based on cutter temperature data corresponding to the brightness features, the color features and the texture features, pre-storing the mapping relation model into the database, wherein the model input is the image features, the output is a temperature estimated value, the model formula is T=a.I 1+b·I2+c·I3 +d, wherein T is the estimated cutter temperature, I 1、I2 and I 3 respectively represent brightness, color and texture feature values extracted from the image, and a, b, c and d are model parameters obtained through training data learning.
In a further preferred example, the training procedure of a, b, c and d comprises that the model parameters are initialized at the beginning usually randomly or according to some heuristic method, for each sample in the training dataset, the input features are substituted into the model (i.e. into the temperature estimation formula) to obtain a predicted temperature value, the difference between the predicted temperature and the real temperature is calculated using the loss function to obtain a loss value, the gradient of the model parameters is calculated by the chain law according to the loss value, the model parameters are updated according to the gradient using the optimization algorithm (gradient descent, random gradient descent, adam), the above steps are repeated until a certain stopping criterion is fulfilled (e.g. a maximum number of iterations is reached, the loss value is below a certain threshold value, the performance of the verification set is no longer improved). Through the process, the model parameters can be gradually adjusted to minimize the difference between the predicted temperature and the actual temperature, so that the model can make more accurate predictions on unseen data, and in the temperature estimation formula, a, b, c and d are learned through the training process.
In a preferred embodiment of the invention, the cutter breakage prediction module extracts the color characteristics and the texture characteristics of the cutter and simultaneously extracts the shape characteristics of the cutter, and is used for judging the cutter abrasion condition, the specific operation process of judging the cutter abrasion condition comprises the steps of storing the cutter color characteristics, the texture characteristics and the shape characteristics under different abrasion conditions in a database, classifying the abrasion degree into the grades q, k1, k2, k3, kn, g and g1, wherein q and g represent the excellent and poor cutter states, k1, k2, k3 and kn are a plurality of grades between the excellent and poor cutter states, g1 represents the incomplete cutter (fracture), setting the grade in a certain range into a state grade which can not work continuously, shooting the cutter in real time during the cutter working process, comparing the cutter color characteristics, the texture characteristics and the shape characteristics with the cutter color characteristics, the texture characteristics and the shape characteristics prestored in the database, obtaining the state grade of the cutter condition, and when the comparison result reaches the preset non-continuous working state grade or the cutter state grade (the fracture state) or the cutter state) which is in g1, controlling the cutter breakage probability by the cutter breakage state and the cutter loss, and the CNC system can be controlled by the cutter loss control system, and the accuracy of the cutter abrasion degree can be improved, and the machining precision can be judged by the cutter CNC system and the cutter abrasion degree is controlled by the cutter breakage and the CNC.
In the preferred embodiment of the invention, after the color features, the shape features and the texture features of the extracted cutter are extracted, image segmentation is carried out to segment the cutter and the workpiece area in the image for monitoring the contact state of the cutter and the workpiece, and the specific operation process comprises the steps of pre-storing the standard range of the contact area, the contact length and the contact angle of the cutter when the workpiece is processed in a database, and setting the threshold range for executing the shutdown or the alarm of a CNC control system in the range; the method comprises the steps of detecting edges of a contact area of a tool and a workpiece through a Canny or Sobel edge detection algorithm to obtain the shape and the size of the contact area, extracting characteristics related to a contact state through a mode of calculating the number of pixels and the geometric shape, wherein the characteristics comprise contact area, contact length and contact angle, evaluating the size of the contact area through calculating the number of pixels or the size of the area of the contact area according to the extracted characteristics, wherein the change of the contact area reflects the abrasion condition of the tool and the change of cutting conditions, evaluating the continuity of the contact of the tool and the workpiece through measuring the length of the contact area, the change of the contact length reflects the stability in the cutting process, evaluating the inclination of the contact of the tool and the workpiece through calculating the angle of the contact area, and detecting whether abnormal conditions exist or not through comparing the current contact state with a pre-stored threshold range difference in a database.
In the preferred embodiment of the invention, the cutter breakage prediction module further comprises cutter working path monitoring, wherein the cutter working path monitoring specific operation process comprises the steps of acquiring or presetting paths of cutters in a CNC control system from the CNC control system and storing the paths in a database, each path comprises a plurality of points, each point comprises X, Y, Z coordinates and a timestamp, a preset X, Y, Z coordinate difference threshold range is stored in the database, X, Y, Z coordinates of the cutters are acquired in real time through an industrial camera shooting by using an image processing module, meanwhile, a current timestamp is acquired, a Euclidean distance algorithm is used for searching coordinate points corresponding to a preset path strength in the database according to the current timestamp, meanwhile, calculating deviation between the coordinates acquired in real time and coordinates corresponding to the time points in the database, comparing the deviation value with a threshold value, obtaining two results, (normal path and deviation path) from the data processing and communication module, outputting the results to the CNC control system, wherein the working path of the cutters is generated through external software, but the working path deviation path is caused by factors such as cutting force and vibration in the cutter working process, and the working risk of the cutter working is reduced when the cutter working path deviation is caused by the fact that the cutter working path is deviated from the original path, and the cutter working risk is reduced due to the fact that the cutter working path is deviated from the cutter working path is broken through monitoring the cutter working risk is simultaneously.
In a further preferred embodiment, the tool movement speed and acceleration are calculated by tool path monitoring, which comprises calculating the tool movement speed first, extracting a time series of X, Y, Z coordinate data from path data acquired or preset in the CNC control system, each data point comprising a coordinate value (X, Y, Z) and a corresponding time stamp, and the time interval between the data points being kept constant, and for each coordinate point (except the first one), obtaining the speed by calculating the displacement and time difference between it and the previous coordinate point, the calculation formula is as follows: Wherein (x 1、y1、z1) and (x 2、y2、z2) are two continuous coordinate points, Δd is a displacement value, the time difference (Δt) between the two continuous coordinate points is continuously obtained, and the moving speed v is equal to the displacement divided by the time difference, and the calculation formula is: In addition to the first two coordinate points, three continuous coordinate points are obtained for calculating the acceleration of the tool, the speed difference Deltav between the two continuous speeds is calculated first, and then the acceleration is calculated by combining the time difference Deltat The method comprises the steps of presetting a moving speed and an acceleration standard value of a cutter in a database, setting a threshold value at the same time, continuously calculating the moving speed and the acceleration of the cutter by a cutter breaking prediction module in the working process of the cutter, comparing the moving speed and the acceleration of the cutter with the moving speed and the acceleration threshold value of the cutter stored in the database in real time, outputting signals to CNC through a data processing and communication module when the comparison result is in a threshold value range, wherein the moving speed and the acceleration of the cutter are one of the factors which most directly cause cutter breaking, and simultaneously carrying out cooperation calculation by a monitoring path so as to monitor the moving speed and the acceleration of the cutter in real time, and timely notifying a CNC control system to react after the moving speed and the acceleration exceed the threshold value, thereby reducing cutter breaking caused by the moving speed and the acceleration.
In a preferred embodiment of the invention, the system further comprises a tool setting monitoring module, the tool setting monitoring module is in communication connection with the image processing module and the database, the tool setting monitoring module monitors whether tool setting operation is performed before the tool works by utilizing pictures shot by the industrial camera and matching with the image processing module, and the specific operation process comprises the following steps: one or more fixed reference points are arranged on a CNC machine tool or a workpiece, the position of the reference point is identified by utilizing an image processing module after shooting by an industrial camera, a distance threshold value between a cutter and the reference point is set in a database, the distance between the cutter and the reference point is calculated in real time, the calculated distance is compared with the threshold value distance, the comparison result is transmitted to the CNC control system through a data processing and communication module, the tool setting monitoring can monitor the tool setting condition during CNC work, the probability that the cutter is calibrated before work is improved, and the tool breaking risk is reduced.
In the preferred embodiment of the invention, the data processing and communication module is composed of a data processing unit and a communication unit, the data processing unit is used for processing, calculating and executing various data, the communication unit is used for receiving and transmitting signals, the data processing and communication module operation process comprises the steps of receiving the data generated by the cutter breakage prediction module in real time, classifying the data, respectively dividing the cutter temperature, cutter abrasion condition, cutter and workpiece contact state, cutter working path, cutter moving speed and cutter acceleration into flash memory and processing, simultaneously storing corresponding standard value and threshold value data for each category in a database, and quickly matching two groups of corresponding data and simultaneously sending the data to the CNC control system and the cutter breakage analysis module after the data processing and communication module receives the data.
In a preferred embodiment of the present invention, the system further includes a breaking analysis module, and an input end of the breaking analysis module is communicatively connected with the data processing and communication module and the database, and is configured to generate a final breaking result, where a specific operation process includes: receiving cutter temperature, cutter abrasion condition, cutter contact state with a workpiece, cutter working path, cutter moving speed and cutter acceleration and cutter working state data output by a data processing and communication module, training a model by using a neural network learning algorithm, recording and analyzing cutter breaking factors, and performing a large amount of training on the model by historical data; when a cutter breaking result appears, the cutter breaking analysis module records the cutter temperature, cutter abrasion condition, cutter contact state with a workpiece, cutter working path, cutter moving speed, cutter acceleration and cutter setting data at the moment of cutter breaking through the neural network learning model, and simultaneously attaches a standard value and a threshold value stored in a database by the data, finally, according to the numerical value exceeding the threshold value, cutter breaking factors are analyzed through the arrangement result, wherein the factors comprise but are not limited to excessively high cutter temperature, serious abrasion, poor contact area/length/angle between the cutter and the workpiece, inconsistent cutter working path, excessively fast cutter moving speed and acceleration and cutter setting according to the standard, various cutter breaking prediction conditions processed by the cutter breaking monitoring module are classified together through the cutter breaking analysis module, the cutter breaking prediction condition is predicted in multiple aspects, meanwhile, instructions can be timely output to a CNC control system after cutter breaking, and loss can be timely reduced when cutter breaking occurs.
In the preferred embodiment of the invention, the image processing module further comprises a video recording unit, the video recording unit is used for extracting videos recorded by the industrial camera when the cutter breaking situation occurs, the video time is shifted forward for 5-10min to obtain cutter breaking phenomenon video segments, the cutter breaking phenomenon video segments are finally transmitted to the cutter breaking analysis module for storage, the video recording unit can record the videos when the cutter breaking occurs, and the video shifting forward for 5-10min can facilitate professionals to judge cutter breaking factors by slowly releasing the whole videos, so that improvement of cutters or CNCs can be made in a targeted mode.
Example 3
On the basis of the above embodiments 1,2, the present invention further provides a computer program product comprising computer instructions for instructing a computing device to execute the CNC cutter breaking monitoring control method according to embodiment 1.
Meanwhile, the invention also provides a computer readable storage medium, on which a computer program is stored, which when executed by a processor, implements the CNC cutter breaking monitoring control method described in the above embodiment 1.
In addition, the specific implementation of each step in the program may refer to the corresponding steps and corresponding descriptions in the units in the above method embodiments, which are not repeated herein. It will be clear to those skilled in the art that, for convenience and brevity of description, specific working procedures of the apparatus and modules described above may refer to corresponding procedure descriptions in the foregoing method embodiments, which are not repeated herein.
The methods, systems according to embodiments of the present invention described above may be implemented in hardware, firmware, or as software or computer code storable in a recording medium such as a CD ROM, RAM, floppy disk, U-disk, hard disk, or magneto-optical disk, or as computer code originally stored in a remote recording medium or a non-transitory machine-readable medium and to be stored in a local recording medium downloaded through a network, so that the methods, systems described herein may be stored on such software processes on recording media using a general purpose computer, special purpose processor, or programmable or special purpose hardware such as an ASIC or FPGA. It is understood that a computer, processor, microprocessor controller, or programmable hardware includes a storage component (e.g., RAM, ROM, flash memory, etc.) that can store or receive software or computer code that, when accessed and executed by a computer, processor, or hardware, implements the methods, systems described herein. Furthermore, when a general purpose computer accesses code for implementing the methods illustrated herein, execution of the code converts the general purpose computer into a special purpose computer for performing the methods, systems illustrated herein.
The preferred embodiments of the invention disclosed above are intended only to assist in the explanation of the invention. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best understand and utilize the invention. The invention is limited only by the claims and the full scope and equivalents thereof.
Claims (9)
1. A CNC cutter breaking monitoring control system at least comprises an image acquisition module, an image processing module, a database, a cutter breaking prediction module, a data processing and communication module and a CNC control execution module, and is characterized in that,
The image acquisition module is arranged in the CNC machine tool or on a tool apron of the CNC machine tool, and is used for continuously shooting the working state of the tool inside the CNC machine tool, acquiring working video data of the tool, and transmitting the acquired video data to the downstream image processing module;
The input end of the image processing module is in communication connection with the image acquisition module and is used for receiving the cutter working video data, extracting a shot image in the video, processing the extracted shot image, wherein the image processing at least comprises enhancement, edge processing and feature extraction, and transmitting image feature data obtained after the image processing to the downstream cutter breaking prediction module;
The method comprises the steps that data related to a standard cutter working state are prestored in a database, wherein the data comprise image characteristic data, wear grade data, a mapping relation model of image characteristics and cutter temperature, and standard ranges and thresholds of cutter temperature, cutter contact state with a workpiece, cutter working path, cutter moving speed and acceleration under different working states, and the image characteristic data at least comprise color characteristics, texture characteristics and shape characteristics corresponding to different cutter wear grades;
the input end of the cutter breakage prediction module is in communication connection with the image processing module and the database, and is used for carrying out comparison and analysis based on the image characteristic data extracted by the image processing module and in combination with the standard cutter related data prestored in the database, comprehensively judging whether a cutter has a breakage precursor or not, and outputting a judging result to a downstream data processing and communication module;
The input end of the data processing and communication module is in communication connection with the cutter breaking prediction module and is used for receiving and classifying the analysis result of the cutter breaking prediction module and transmitting the result to the CNC control execution module;
The input end of the CNC control execution module is in communication connection with the data processing and communication module and is used for generating a control instruction according to an analysis result and performing operations of stopping, alarming or adjusting processing technological parameters based on the control instruction;
In the working process of the cutter, an industrial camera in the image acquisition module shoots a cutter image in real time, the image is processed by the image processing module to obtain the current brightness characteristic, color characteristic and texture characteristic of the cutter and transmitted to the cutter breakage prediction module, the cutter breakage prediction module compares the obtained current image characteristic data with the pre-stored brightness characteristic, color characteristic and texture characteristic of the cutter in a database and obtains the cutter temperature under the current image characteristic based on a mapping relation model of the pre-stored image characteristic and the cutter temperature in the database, when the cutter temperature reaches a cutter temperature threshold range set in the database, the cutter breakage risk is represented, a signal is sent to a CNC control system through the data processing and communication module, and the CNC control system executes stopping, alarming or other operations of the cutter;
And, the mapping relation model of the image characteristic and the cutter temperature in the database is constructed, comprising:
Collecting image data in the working process of the cutter, extracting brightness characteristics, color characteristics and texture characteristics of the image data, simultaneously recording the actual cutter temperature corresponding to each characteristic, storing the actual cutter temperature into a database, simultaneously setting a cutter temperature threshold range in the database,
Based on cutter temperature data corresponding to brightness features, color features and texture features, a linear regression statistical learning method is used for establishing a mapping relation between cutter temperature and image features, the mapping relation is prestored in a database, model input is the image features, output is a temperature estimated value, and a model formula is as follows:
Where T is the estimated tool temperature, I 1、I2 and I 3 represent the luminance, color and texture feature values extracted from the image, respectively, and a, b, c and d are model parameters learned by training data.
2. The CNC cutter breakage monitoring control system according to claim 1, wherein the cutter breakage prediction module extracts the shape feature of the cutter while extracting the color feature and the texture feature of the cutter, and is used for judging the wear condition of the cutter, and the specific operation process for judging the wear condition of the cutter comprises:
storing color features, texture features and shape features of the cutter under different abrasion conditions in a database, classifying the abrasion degree into q, k1, k2, k3, kn, g and g1 grades, wherein q and g represent excellent and poor states of the cutter, k1, k2, k3 and kn are a plurality of grades in the middle of the excellent and poor states, g1 represents the incomplete state of the cutter fracture, and setting the grade in a certain range as a state grade which cannot work continuously;
in the working process of the cutter, the cutter is photographed in real time, the color characteristics, the texture characteristics and the shape characteristics of the cutter are extracted by an image processing module, and compared with the color characteristics, the texture characteristics and the shape characteristics of the cutter pre-stored in a database, so that the state grade of the abrasion condition of the cutter is obtained;
When the comparison result reaches the preset grade of the unable to continue working state or the cutter abrasion condition is in the g1 state, the data processing and communication module outputs signals to the CNC control system, and the CNC control system makes output signals for stopping working.
3. The CNC cutter breakage monitoring control system according to claim 2, wherein the image segmentation is performed after the extracted color features, shape features and texture features of the cutter, and the cutter and the workpiece area in the image are segmented for monitoring the contact state of the cutter with the workpiece, and the specific operation process comprises:
Pre-storing a standard range of contact area, contact length and contact angle of a cutter when a workpiece is machined in a database, and setting a threshold range for executing shutdown or alarm of a CNC control system in the range;
Detecting the edges of a contact area of a cutter and a workpiece through an edge detection algorithm to obtain the shape and the size of the contact area, and extracting the characteristics related to the contact state through calculating the number of pixels and the geometric shape, wherein the characteristics comprise a contact area, a contact length and a contact angle;
According to the extracted characteristics, the size of the contact area is estimated by calculating the number of pixels or the size of the area of the contact area, the continuity of the contact of the cutter with the workpiece is estimated by measuring the length of the contact area, and the inclination of the contact of the cutter with the workpiece is estimated by calculating the angle of the contact area;
detecting whether an abnormal condition exists or not by comparing the current contact state with a pre-stored threshold range difference in a database, wherein the abnormal condition comprises reduction of a contact area, change of a contact length and abnormal change of a contact angle, when the current contact state reaches the threshold range, the current cutter is represented to have high fracture risk, and a data processing and communication module outputs a signal to a CNC control system.
4. The CNC cutter break monitoring control system of claim 1, wherein the cutter break prediction module further comprises cutter working path monitoring, the specific operation process comprising:
Acquiring or presetting paths of a cutter in a CNC control system from the CNC control system and storing the paths in a database, wherein each path comprises a plurality of points, each point comprises x, y and z coordinates and a time stamp, presetting an x, y and z coordinate difference threshold range, storing the x, y and z coordinate difference threshold range in the database, shooting by an industrial camera in the image acquisition module, acquiring the x, y and z coordinates of the cutter in real time by using the image processing module, and acquiring the current time stamp;
Searching coordinate points of corresponding time periods on a preset path in a database according to a current timestamp by using an Euclidean distance algorithm, calculating deviation between coordinates acquired in real time and coordinates of corresponding time points in the database, comparing the deviation value with a threshold value to obtain two results of a normal path and a deviation path, and outputting the results to a CNC control system by a data processing and communication module.
5. The CNC cutter break monitoring control system of claim 4, wherein the cutter movement speed and acceleration are calculated by the cutter working path monitoring, the specific process comprising:
Firstly, calculating the moving speed of a cutter, extracting x, y and z coordinate data of a time sequence from path data acquired or preset in a CNC control system, wherein each data point comprises coordinate values (x, y and z) and corresponding time stamps, and the time interval between the data points is kept constant;
For each coordinate point, except for the first coordinate point, the speed is obtained by calculating the displacement and time difference between the coordinate point and the previous coordinate point, and the calculation formula is as follows:
Wherein (x 1、y1、z1) and (x 2、y2、z2) are two consecutive coordinate points, Δd is a displacement value;
Continuously acquiring a time difference delta t between two continuous coordinate points;
The moving speed v is equal to the displacement divided by the time difference, and the calculation formula is as follows: ;
In addition to the first two coordinate points, three continuous coordinate points are obtained for calculating the acceleration of the tool, the speed difference Deltav between the two continuous speeds is calculated first, and then the acceleration is calculated by combining the time difference Deltat ;
And presetting a tool moving speed and acceleration standard value in a database, setting a threshold value at the same time, continuously calculating the tool moving speed and the tool acceleration by a tool breaking prediction module in the tool working process, comparing the tool moving speed and the tool acceleration with the tool moving speed and tool acceleration threshold value stored in the database in real time, and outputting a signal to CNC (computerized numerical control) through a data processing and communication module when the comparison result is in a threshold value range.
6. The CNC cutter breakage monitoring control system according to claim 1, further comprising a cutter setting monitoring module, wherein an input end of the cutter setting monitoring module is in communication connection with the image processing module and the database, the cutter setting monitoring module monitors whether the cutter setting operation is performed before the cutter work by using a picture shot by an industrial camera in the image acquisition module in cooperation with the image processing module, and the specific operation process comprises:
Setting one or more fixed reference points on a CNC machine tool or a workpiece, shooting by an industrial camera in the image acquisition module, utilizing the image processing module to identify the position of the reference point, setting a distance threshold between a cutter and the reference point in a database, calculating the distance between the cutter and the reference point in real time, comparing the calculated distance with the threshold distance, and transmitting the comparison result to a CNC control system through the data processing and communication module.
7. The CNC knife break monitoring control system of claim 6, further comprising a knife break analysis module, wherein an input of the knife break analysis module is communicatively connected to the data processing and communication module and the database for generating a final knife break result, and wherein the specific operation process comprises:
Receiving cutter temperature, cutter abrasion condition, cutter contact state with a workpiece, cutter working path, cutter moving speed and cutter acceleration cutter working state data output by the data processing and communication module, training a model by using a neural network learning algorithm, recording and analyzing cutter breaking factors, and training a large number of models by historical data;
When the cutter breaking result appears, the cutter breaking analysis module records the cutter temperature, cutter abrasion condition, cutter contact state with a workpiece, cutter working path, cutter moving speed, cutter acceleration and cutter setting data of the cutter breaking at the moment through the neural network learning model, and simultaneously attaches a standard value and a threshold value stored in a database by the data, finally, according to the numerical value exceeding the threshold value, cutter breaking factors are analyzed from large to small according to the arrangement result, wherein the cutter breaking factors comprise overhigh cutter temperature, serious abrasion, poor contact area/length/angle of the cutter and the workpiece, inconsistent cutter working path, excessively fast cutter moving speed and acceleration and cutter setting according to the standard.
8. The CNC knife break monitoring control system according to claim 7, wherein the data processing and communication module is composed of a data processing unit and a communication unit, the data processing unit is used for processing, calculating and executing various data, the communication unit is used for receiving and transmitting signals, and the operation process of the data processing and communication module comprises:
The data processing unit receives the data generated by the cutter breakage prediction module in real time, classifies the data, respectively separates the cutter temperature, cutter abrasion condition, cutter and workpiece contact state, cutter working path, cutter moving speed and cutter acceleration into flash memories and processes, stores corresponding standard values and threshold data for each category in the database, and rapidly matches two groups of corresponding data after the data processing and communication module receives the data, and simultaneously sends the data to the CNC control system and the cutter breakage analysis module.
9. The CNC cutter breaking monitoring control system according to claim 7, wherein the image processing module further comprises a video recording unit, the video recording unit is used for extracting a video recorded by the industrial camera when the cutter breaking occurs, and pushing the video for 5-10min to obtain a cutter breaking phenomenon video segment, and the cutter breaking phenomenon video segment is finally transmitted to the cutter breaking analysis module for storage.
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