CN104308060B - A kind of method for supervising of the on-line monitoring system for steel ball cold heading shaping - Google Patents
A kind of method for supervising of the on-line monitoring system for steel ball cold heading shaping Download PDFInfo
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- CN104308060B CN104308060B CN201410527836.7A CN201410527836A CN104308060B CN 104308060 B CN104308060 B CN 104308060B CN 201410527836 A CN201410527836 A CN 201410527836A CN 104308060 B CN104308060 B CN 104308060B
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- steel ball
- displacement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J13/00—Details of machines for forging, pressing, or hammering
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/02—Making machine elements balls, rolls, or rollers, e.g. for bearings
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
- G01B7/02—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
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Abstract
The invention discloses a kind of method for supervising of the on-line monitoring system for steel ball cold heading shaping, comprise dynamic and static mould displacement signal acquisition device, displacement signal acquisition device is connected with single-chip computer control system, single-chip computer control system is connected with man-machine interface, described dynamic and static mould displacement signal acquisition device gathers the change in displacement between dynamic model, quiet mould, and change in displacement is converted into change in voltage; Described voltage signal is transferred to single-chip computer control system, and described single-chip computer control system shows after processing voltage signal in man-machine interface.The present invention is increased in line monitoring system on the basis of traditional cold-heading process, production efficiency is improved greatly, problem in Timeliness coverage cold-heading process, in the labor-saving consistance that improve product quality simultaneously, achieves the on-line monitoring be shaped for cold-heading process ball base.
Description
Technical field
The present invention relates to a kind of method for supervising of the on-line monitoring system for steel ball cold heading shaping.
Background technology
Steel ball, as the vital part in mechanized equipment field, is mainly used in bearing, valve, lead screw transmission, polishing etc., is machinery, automobile industry and military project, the requisite part of aerospace industry.The basic machining process of current domestic steel ball is: starting material → cold-heading → photosphere → thermal treatment → hard grind → early grind → lappingout → superfinishing grinds → optical appearance → cleaning rust-proof → product inspection → packaging.Cold-heading base can ensure good Product Precision and mechanical property, and thus middle-size and small-size steel ball base generally adopts cold-heading processing technology.Cold-heading is as the first operation of steel ball processing, and its defect that becomes second nature has diffusivity, heredity, disguise, often comes out in subsequent handling, is main hidden danger of quality and substandard products source.Endless belt defect (without endless belt or endless belt excessive) be the prevailing quality defect that steel ball is embarked on journey in process.
Current domestic steel ball cold heading equipment only performs mechanical to-and-fro movement, lacks process and detects; Traditional employing dedicated test utensil carries out the method for manual detection, and detection efficiency is low, and measurer is easy to wear, in production run, problem can not by Timeliness coverage and correction, cause blank quality poor stability, often mix bad product in qualified steel ball blanks, have a strong impact on product qualified rate.
It is the automatic detection device disclosing a kind of steel ball high-speed cold heading machine in [201310519608.0] at number of patent application, , comprise the PLC be fixed in cold headers frame, cold headers panel 1, module 2, fixing formwork 3, fixing ball mould 4, movable formwork 5 and movable balls mould 6, described module 2 is fixedly connected with cold headers panel 1, fixing formwork 3 is fixedly mounted in module 2 by backing plate 9, fixing ball mould 4 is arranged in fixing formwork 3, movable balls mould 6 is arranged in movable formwork 5, movable formwork 5 is connected with the high-speed electric expreess locomotive of cold headers by eccentric wheel, this automatic detection device also comprises pressure transducer 7, the panel 1 of cold headers is provided with hole 8, and load pressure transducer 7 in hole 8, pressure transducer 7 is connected with PLC on cold headers by wire,
The automatic detection device of existing patent, pressure transducer needs to be arranged in the hole on cold headers panel, installs inconvenient, and carry out scrap build trouble on the basis of existing cold headers, need again to punch sensor installation; Adopt PLC to control, cost is higher.And the value only by obtaining surge pressure is come to judge that method that whether ball is qualified is comprehensive according to pressure limit, should according to pressure in cold-heading process--time signal sets up enveloping curve judgement.
Summary of the invention
In order to solve the deficiency that prior art exists, the invention discloses a kind of on-line monitoring system be shaped for steel ball cold heading, by to dynamic model in cold-heading process, quiet mould displacement signal carries out Real-Time Monitoring and record, and automatically set up production monitoring standard by self-learning algorithm, On-line testing monitoring also analytic signal feature, Real-Time Monitoring cold heading sphere blank time-displacement curve in process, by the matching degree of correlation analysis algorithm analysis and production monitoring standard, make there is problem in production run by Timeliness coverage, there is quality tracing and optimization, the function such as abnormal alarm and equipment protection.
For achieving the above object, concrete scheme of the present invention is as follows:
A kind of on-line monitoring system be shaped for steel ball cold heading, comprise dynamic and static mould displacement signal acquisition device, displacement signal acquisition device is connected with single-chip computer control system, single-chip computer control system is connected with man-machine interface, described dynamic and static mould displacement signal acquisition device gathers the change in displacement between dynamic model, quiet mould, and change in displacement is converted into change in voltage; Described voltage signal is transferred to single-chip computer control system, and described single-chip computer control system shows after processing voltage signal in man-machine interface.
Described dynamic and static mould displacement signal acquisition device comprises micrometric displacement current vortex sensor, be arranged on cold headers fixes the fixed support on formwork and to be arranged on movable formwork and for the fixing sensor block of sensor sensing; Described micrometric displacement current vortex sensor is arranged on fixed support.
Described single-chip computer control system mainly comprises singlechip chip, A/D modular converter, warning device.A/D modular converter is all connected with singlechip chip with warning device;
Described warning device mainly comprises relay and red alarm lamp, and relay controls the break-make of alarm lamp circuit;
Described man-machine interface is touch screen human-computer interface, is connected with the serial communication of singlechip chip by Serial Port Line;
Described micrometric displacement current vortex sensor, single-chip computer control system, man-machine interface are all powered by Systematical control power circuit;
Described Systematical control power circuit comprises rotary switch, power light and technical grade AC-DC Switching Power Supply, and 220V alternating current is converted to 24V and 5V direct current and exports by AC-DC Switching Power Supply.
Micrometric displacement current vortex sensor is by the principle of eddy current effect, and the relative position of Measurement accuracy measured body (must be metallic conductor) and probe end face, and change in displacement is converted into change in voltage.Micrometric displacement current vortex sensor and sensor block are arranged on quiet mould and dynamic model side respectively, and in production run, the distance change transitions of cold-heading carcass is voltage change signal.
Dynamic and static mould displacement signal acquisition device be used in cold-heading process between dynamic model, quiet mould the signal of change in displacement gather;
Man-machine interface is for showing running parameter and the cold headers duty of displacement signal in cold-heading process;
Single-chip computer control system is delivered to man-machine interface after being used for the displacement signal process collected by displacement transducer and is shown in real time, by self-learning algorithm, the displacement signal in one section of steady production process is recorded, and automatically set up enveloping curve as production monitoring standard, Real-Time Monitoring cold heading sphere blank time-displacement curve in process, by the matching degree of correlation analysis algorithm analysis and production monitoring standard, produce alerting signal when actual production process test signal exceeds enveloping curve or automatically close plant equipment power supply;
The method for supervising of described on-line monitoring system is as follows:
First be that learning training process is carried out to monitoring system, set up working template by learning training, mainly comprise 3 steps:
Step 1: under the monitoring of operating personnel, and judge that whether the quality that steel ball is shaped is qualified by operating personnel, only record the time m-displacement signal of qualified steel ball blanks;
Step 2: discrete sampling is carried out to qualified steel ball blanks, specific as follows:
To n cold-heading steel ball qualifying signal sampling; Each signal through A/D conversion after, the discrete array [x being a length and being fixed as j
ij] (i=1,2 ... n), (j=1,2 ... N); Be discrete point by each load signal by continuous analog quantitative change like this, for medium filtering provides numerical value to originate.Be discrete point by each load signal by continuous analog quantitative change like this, for medium filtering provides numerical value to originate.
Step 3: circle median filter:
Carry out ascending order arrangement to each corresponding point in n group data, x (x > 3) the individual data in the middle of selecting are preserved; If there is new data, then carry out the sampling of n-x group waveform, composition n group data, ascending order arranges; But which is recorded is the legacy data remained in the past, and which is new data; According to the various different arrangements possibility of new legacy data, obtain the waveform signal that x group is new, so circulate.If do not have new Waveform Input, from the remaining x of an each some data, the data in the middle of selecting are preserved, and obtain reference waveform signal, automatically set up enveloping curve as production monitoring standard, be kept in Single Chip Microcomputer (SCM) system;
N above, x all represents natural number.
After monitoring system has carried out learning training, enter the normal production work stage, entered into step 4.Under nominal situation, each cold-heading process time m-displacement signal curve characteristic index substantially identical with template, once there is shaping fault, signal curve will produce corresponding ANOMALOUS VARIATIONS.
Step 4: when the production phase is detected, dynamic and static mould displacement signal is gathered at any time by micrometric displacement current vortex sensor, adopt correlation analysis algorithm that the production monitoring standard in gathered signal and step 3 is carried out matching operation, produce alerting signal when actual production process test signal exceeds enveloping curve or automatically close plant equipment power supply, when not exceeding enveloping curve, equipment normally runs.
Beneficial effect of the present invention:
Adopt the relation of micro-displacement sensor monitoring dynamic model displacement x t change in time in the present invention, gather the Changing Pattern of material section forming quality in forming process, adopt self-learning algorithm automatically to set up enveloping curve as production monitoring standard, the width of optimum envelope curve can be calculated by automatic analysis according to the every bit on displacement curve.In actual production process, when die wear, material section are elongated, the link such as to shorten occurs abnormal, displacement signal change will reflect on enveloping curve;
The present invention is increased in line monitoring system on the basis of traditional cold-heading process, production efficiency is improved greatly, problem in Timeliness coverage cold-heading process, in the labor-saving consistance that improve product quality simultaneously, achieves the on-line monitoring be shaped for cold-heading process ball base.
Accompanying drawing explanation
Fig. 1 steel ball cold heading mechanism schematic diagram;
Fig. 2 (a)-(b) automatic learning enveloping curve schematic diagram;
Fig. 3 standard signal learning algorithm process flow diagram;
Fig. 4 sensor installation diagram;
Fig. 5 single-chip computer control system figure;
Fig. 6 systematic functional structrue figure;
In figure: 1. eccentric wheel 2. connecting rod 3. slide block 4. adjustment block 5. dynamic model 6. cover half.
Embodiment
Below in conjunction with accompanying drawing, the present invention is described in detail:
Be the structural principle sketch of cold-heading campaign as shown in Figure 1, figure comprises eccentric wheel 1, connecting rod 2, slide block 3, adjustment block 4 dynamic model 5, cover half 6.Ball cold header cold-heading process can be reduced to slider-crank mechanism and drive dynamic model motion, thus makes bar crimp between dynamic and static mould, final cold-heading balling-up.Wherein adjustment block can adjust up and down, for regulating the range of dynamic model (namely adjusting the final position of dynamic model), thus the endless belt size of adjustment steel ball blanks.
Set up coordinate system in the drawings, calculate the relational expression of displacement x about angle θ of slide block.Because slide block and eccentric deflection center are coaxial, therefore in △ OAB, the horizontal ordinate of OB, namely dynamic model displacement movement equation is:
Due to θ=ω t, substitute into above formula, dynamic model displacement be converted into displacement movement function in time with the characteristics of motion of angle:
When cold headers are unloaded, dynamic model displacement x with the movement function of angle θ, time t as shown in two formula above.When in actual cold upsetting production process, have ess-strain produce from material section to the process of cold-heading balling-up base, material section can produce reacting force to dynamic model in the process of cold-heading, and reacting force can make crank, connecting rod produce elastic deformation.Therefore, in the process of punching press cold-heading, dynamic model displacement x will be no longer above described in formula with the movement function relation of angle θ, time t, and certain change can occur.
Based on above-mentioned principle, the invention discloses the on-line monitoring system be shaped for steel ball cold heading, comprise dynamic and static mould displacement signal acquisition device, displacement signal acquisition device is connected with single-chip computer control system, and single-chip computer control system is connected with man-machine interface;
The displacement signal acquisition device fixed support of installing micrometric displacement current vortex sensor and sensor block that displacement transducer is responded to as shown in Figure 4, displacement transducer is fixed in the hole of support, by two threaded hole screw fastenings on top, four screws of support both sides are fixed on fixing formwork side.Sensor has that functional reliability is good, measurement range is wide, highly sensitive, resolution is high, fast response time, interference resistance by force, not by advantages such as medium influence such as greasy dirts.The displacement signal collected is converted into voltage signal and sends into single-chip microcomputer;
Single-chip computer control system comprises singlechip chip as shown in Figure 5, A/D modular converter, warning device.A/D modular converter is all connected with singlechip chip with alarm output device, and man-machine interface is communicated by UART0 with single-chip microcomputer;
Being illustrated in figure 6 the design drawing of system man-machine interface, mainly containing four interfaces composition, is 1. starting-up interface, 2. homepage interface, 3. mode of learning interface, 4. optimum configurations interface respectively.
In use, open the rotary switch in system power supply circuit, power light is bright, first shows starting-up interface after man-machine interface powers on, and clicks in starting-up interface and enters into homepage interface after " entering "; Order volume, actual performance, order surplus, information such as residue process time, processing speed etc. can be shown in real time on the left of homepage interface, right side comprises the options such as mode of learning, production model, optimum configurations, help, center section is displacement information viewing area, as long as shown in real time with the form of histogram by the displacement collected; After click " mode of learning " enters into mode of learning, display mode of learning interface, mode of learning is started after " startup " is clicked at mode of learning interface, interface display is learning and recording learning result, within 1-2 minute, click " stopping " button later, now then display learning outcome is preserved by drawing frame, sets up production monitoring standard; Under production model, drawing frame shows displacement information change that sensor collects in real time and compares with the production monitoring standard set up, when larger with monitoring standard difference in a period of time, and warning device work, remind workman to shut down, continue after regulating cold headers to produce; The parameter of Drawing zone X-axis with Y-axis can be set at optimum configurations interface.
Main function of system:
(1) quality analysis: on-line analysis displacement signal, sets up production monitoring standard, differentiates forming defects;
(2) data store and read: utilize the inner FLASH of human machine interface screen, by process data, production leadtime information etc. is stored into system;
(3) display module: realize visualized operation, interactive setting.Realize the real-time display of significant data, comprising: the histogram, operation setting menu etc. of performance graph, impact energy;
(4) time tag: machining information is corresponding with process time, realizes product and adds up in shifts and inquire about with historical record;
(5) setting parameter: man-machine interactive arranges important parameter, as internal gain, displacement signal sampling rate etc.;
(6) important parameter power-failure memory: preserve the parameter set, start is read automatically, and the monitoring device of non-first use exempts to arrange.
Adopt the relation of micro-displacement sensor monitoring dynamic model displacement x t change in time in the present invention, gather the Changing Pattern of material section forming quality in forming process, adopt self-learning algorithm automatically to set up enveloping curve as production monitoring standard, the width of optimum envelope curve can be calculated by automatic analysis according to the every bit on displacement curve.In actual production process, when die wear, material section are elongated, the link such as to shorten occurs abnormal, displacement signal change will reflect, if Fig. 2 is automatic learning enveloping curve schematic diagram on enveloping curve;
When the on-line monitoring system that steel ball cold heading is shaped runs learning algorithm, under the monitoring of operating personnel, judge that whether the quality that steel ball is shaped is qualified by operating personnel, only record the displacement signal of qualified steel ball blanks.List standard signal learning algorithm flow process as shown in Figure 3, obtain discretize load signal data point by data acquisition, the study of whole waveform is modified to the study to point.Mainly contain sample variance and circle median filter two step.
(1) sample variance: carry out n cold-heading steel ball qualifying signal sampling; Each signal through A/D conversion after, the discrete array [x being a length and being fixed as N
iN] (i=1,2 ... n).Be discrete point by each load signal by continuous analog quantitative change like this, for medium filtering provides numerical value to originate.
(2) circle median filter: carry out ascending order arrangement to each corresponding point in n group data, 3 data in the middle of selecting are preserved.If there is new data, then carry out the sampling of n-3 group waveform, composition n group data, ascending order arranges; But which is recorded is the legacy data remained in the past, and which is new data.Because legacy data is through screening, the quantity of information comprised is larger than new data, and its right of priority is high, according to the various different arrangement of new legacy data may, obtain 3 groups of new waveform signals, so circulate.If do not have new Waveform Input, from remaining 3 data of each point, the data in the middle of selecting are preserved, and obtain reference waveform signal.
Claims (7)
1. for the method for supervising of the on-line monitoring system of steel ball cold heading shaping, it is characterized in that, on-line monitoring system comprises dynamic and static mould displacement signal acquisition device, displacement signal acquisition device is connected with single-chip computer control system, single-chip computer control system is connected with man-machine interface, described dynamic and static mould displacement signal acquisition device gathers the change in displacement between dynamic model, quiet mould, and change in displacement is converted into change in voltage; Described voltage signal is transferred to single-chip computer control system, and described single-chip computer control system shows after processing voltage signal in man-machine interface; Method for supervising comprises the steps:
Step 1: under the monitoring of operating personnel, and judge that whether the quality that steel ball is shaped is qualified by operating personnel, only record the time m-displacement signal of qualified steel ball blanks;
Step 2: discrete sampling is carried out to qualified steel ball blanks, specific as follows:
To n cold-heading steel ball qualifying signal sampling; Each signal through A/D conversion after, the discrete array [x being a length and being fixed as j
ij] (i=1,2 ... n), (j=1,2 ... N); Be discrete point by each load signal by continuous analog quantitative change like this, for medium filtering provides numerical value to originate;
Step 3: circle median filter:
Carry out ascending order arrangement to each corresponding point in n group data, x (x > 3) the individual data in the middle of selecting are preserved; If there is new data, then carry out the sampling of n-x group waveform, composition n group data, ascending order arranges; But which is recorded is the legacy data remained in the past, and which is new data; According to the various different arrangements possibility of new legacy data, obtain the waveform signal that x group is new, so circulate; If do not have new Waveform Input, from the remaining x of an each some data, the data in the middle of selecting are preserved, and obtain reference waveform signal, automatically set up enveloping curve as production monitoring standard, be kept in Single Chip Microcomputer (SCM) system;
After monitoring system has carried out learning training, enter the normal production work stage, entered into step 4;
Step 4: when the production phase is detected, dynamic and static mould displacement signal is gathered at any time by micrometric displacement current vortex sensor, adopt correlation analysis algorithm that the production monitoring standard in gathered signal and step 3 is carried out matching operation, produce alerting signal when actual production process test signal exceeds enveloping curve or automatically close plant equipment power supply, when not exceeding enveloping curve, equipment normally runs.
2. the method for supervising of the on-line monitoring system be shaped for steel ball cold heading as claimed in claim 1, is characterized in that: described dynamic and static mould displacement signal acquisition device comprises micrometric displacement current vortex sensor, be arranged on cold headers fixes the fixed support on formwork and to be arranged on movable formwork and for the fixing sensor block of sensor sensing; Described micrometric displacement current vortex sensor is arranged on fixed support.
3., as claimed in claim 1 for the method for supervising of the on-line monitoring system of steel ball cold heading shaping, it is characterized in that: described single-chip computer control system comprises singlechip chip, A/D modular converter, warning device; A/D modular converter is all connected with singlechip chip with warning device.
4., as claimed in claim 3 for the method for supervising of the on-line monitoring system of steel ball cold heading shaping, it is characterized in that: described warning device mainly comprises relay and red alarm lamp, and relay controls the break-make of alarm lamp circuit.
5., as claimed in claim 1 for the method for supervising of the on-line monitoring system of steel ball cold heading shaping, it is characterized in that: described man-machine interface is touch screen human-computer interface, is connected with the serial communication of singlechip chip by Serial Port Line.
6., as claimed in claim 2 for the method for supervising of the on-line monitoring system of steel ball cold heading shaping, it is characterized in that: described micrometric displacement current vortex sensor, single-chip computer control system, man-machine interface are all powered by Systematical control power circuit.
7. as claimed in claim 6 for the method for supervising of the on-line monitoring system of steel ball cold heading shaping, it is characterized in that: described Systematical control power circuit comprises rotary switch, power light and technical grade AC-DC Switching Power Supply, 220V alternating current is converted to 24V and 5V direct current and exports by AC-DC Switching Power Supply.
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| CN110553686A (en) * | 2019-10-12 | 2019-12-10 | 重庆四标精密零部件制造有限公司 | Cold header running state monitoring system |
| CN114299308A (en) * | 2021-12-20 | 2022-04-08 | 中用科技有限公司 | Intelligent detection system and method for damaged road guardrail |
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| CN1657863A (en) * | 2005-01-31 | 2005-08-24 | 中南大学 | Non-contact stress measuring device for large structure frame |
| CN102322791A (en) * | 2011-07-21 | 2012-01-18 | 山东大学 | Automatic test system for model test displacement data and test method thereof |
| CN202632009U (en) * | 2012-06-20 | 2012-12-26 | 青岛橡六输送带有限公司 | Vulcanization stretch monitoring system of conveyer belt |
| CN103017647A (en) * | 2012-12-12 | 2013-04-03 | 江苏大学 | Detecting method for displacement of hydraulic counter-blow hammer heads |
| CN103551478A (en) * | 2013-10-30 | 2014-02-05 | 安庆机床有限公司 | Automatic detection device for high-speed steel ball cold header |
| CN204159809U (en) * | 2014-10-09 | 2015-02-18 | 济南大学 | A kind of on-line monitoring system be shaped for steel ball cold heading |
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2014
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Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1657863A (en) * | 2005-01-31 | 2005-08-24 | 中南大学 | Non-contact stress measuring device for large structure frame |
| CN102322791A (en) * | 2011-07-21 | 2012-01-18 | 山东大学 | Automatic test system for model test displacement data and test method thereof |
| CN202632009U (en) * | 2012-06-20 | 2012-12-26 | 青岛橡六输送带有限公司 | Vulcanization stretch monitoring system of conveyer belt |
| CN103017647A (en) * | 2012-12-12 | 2013-04-03 | 江苏大学 | Detecting method for displacement of hydraulic counter-blow hammer heads |
| CN103551478A (en) * | 2013-10-30 | 2014-02-05 | 安庆机床有限公司 | Automatic detection device for high-speed steel ball cold header |
| CN204159809U (en) * | 2014-10-09 | 2015-02-18 | 济南大学 | A kind of on-line monitoring system be shaped for steel ball cold heading |
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