CN104656633A - Detecting method for early failure of logistics trolley of flexible manufacturing system - Google Patents
Detecting method for early failure of logistics trolley of flexible manufacturing system Download PDFInfo
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- CN104656633A CN104656633A CN201410807363.6A CN201410807363A CN104656633A CN 104656633 A CN104656633 A CN 104656633A CN 201410807363 A CN201410807363 A CN 201410807363A CN 104656633 A CN104656633 A CN 104656633A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0221—Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
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Abstract
The invention discloses a detecting method for early failure of a logistics trolley of a flexible manufacturing system. The detecting method comprises the following steps: (1) feeding speed test step: if defects do not exist through diagnosis in the step (1), conducting next step; (2) loading running test step: if defects do not exist through diagnosis in the step (2), conducting next step continuously; (3) treatment after tests: (1) unloading a saddle weight; hoisting the saddle weight to a depository; (2) cleaning and maintaining the logistics trolley. The detecting method conducts early failure motivation on the importance functional unit of flexible manufacture system logistics system logistics trolley in a test manner, finds potential defects in producing and manufacturing process or design, provides a practical method to improve the reliability of a complete machine of a machine tool, greatly reduces early failure probability of machine tools, provides a reference base for diagnosing whether defects exist or not in design of the machine tool, so as to improve machine tool design.
Description
Technical field
The present invention relates to a kind of by the fault detection method excited for the purpose of early stage flexible manufacturing system fault, particularly relate to a kind of critical function parts logistics trolley as flexible manufacturing system, strenuous test is carried out to carry out the method for incipient fault detection to it.
Background technology
Flexible manufacturing system is made up of unified management information system, material handling system and set of number controlled working equipment, can adapt to the automated machine manufacturing system (Flexible Manufacturing System) of processing object conversion, english abbreviation is FMS.Known according to the research of flexible manufacturing system reliability modeling technique, flexible manufacturing system is primarily of system of processing, logistics system, tooling system, control system and backup system five subsystem compositions.By carrying out tracking statistics to flexible manufacturing system, result shows that system re-uses in process after dispatching from the factory, and its inefficacy and the probability broken down are tub curve in time.There is an earlier failure period in flexible manufacturing system, in this time period, the probability that lathe breaks down is comparatively large, and this fault is called initial failure after dispatching from the factory.
In flexible manufacturing system, system of processing forms primarily of machining center; Logistics system is made up of transmitting device, logistics trolley, mechanical arm etc.; The local communication network of control system needed for the automatic operations such as controlled working center, materials conveying system and central control computer, sensor, on-line monitoring equipment and various management and supervision software form; Backup system mainly comprises the equipment such as Workpiece detecting device and cleaning machine composition.Show according to data, logistics system, tooling system, backup system and process equipment are the subsystems of flexible manufacturing system Frequent Troubles.In order to improve the reliability of flexible manufacturing system, be necessary to carry out intensive research to its integrity problem.
Logistics system is the important ingredient of flexible manufacturing system, its major function be realize material and have the automatic transportation between lathe at machining tool and storage sites, carry, deposit etc. work.And logistics trolley groundwork has been station for assembling/disassembling work-pieces
machining center
supporting plate thesaurus
workpiece conveying between workpiece cleaning station, belongs to point-to-point position control system.Motor functions all in logistics system all concentrates on logistics trolley, the nucleus equipment of whole flexible manufacturing system logistics system in fact, once break down, by impact operation completely, and according to statistics, logistics trolley breaks down and accounts for the out of order moon 1/5, has a strong impact on system reliability service, and partial fault is important fault.
For this reason, by test, initial failure is carried out to logistics trolley and excite, with the latent defect finding the design of these parts, processing and assembling to cause before being put into flexible manufacturing system, significant.At present, to excite the test method of reliably feeling at ease for the purpose of initial failure also not have, the reliability attached it on complete machine cannot be ensured, because also the reliability of whole flexible manufacturing system just cannot be ensured about carrying out flexible manufacturing system logistics trolley.
Therefore how to design one and can excite logistics trolley initial failure, to find the incipient fault detection method of logistics trolley latent defect before flexible manufacturing system is dispatched from the factory, becoming this area has problem to be solved.
Summary of the invention
For above-mentioned the deficiencies in the prior art, technical matters to be solved by this invention is: how to provide a kind of flexible manufacturing system logistics trolley incipient fault detection method that can excite logistics trolley initial failure, thus find out its latent defect, create conditions for improving reliability of dispatching from the factory.
In order to solve the problems of the technologies described above, present invention employs following technical scheme:
A kind of flexible manufacturing system logistics trolley incipient fault detection method, comprises the following steps,
(1) speed of feed test procedure: described speed of feed test procedure comprises and being 1. directly mounted in the flexible manufacturing system of test battery by logistics trolley qualified to performance, accuracy test, and debugging its basic function good; Test adopts the mode of logistics trolley independent operating to carry out, therefore require in process of the test, to ensure that the positions such as loading and unloading station, cleaning machine, host tray exchange frame do not have pallet, in order to avoid test causes device damage and personal damage because interfering phenomenon, and the power supply of the system without interaction such as main frame, cleaning machine, loading and unloading station in cutting system in process of the test, ensure can not start in system without interaction process of the test; 2. by logistics trolley respectively with the rapid traverse speed of 1000mm/min, 5000mm/min, 20000mm/min, 60000mm/min, 80000mm/min, 100000mm/min at X to full stroke range of motion 5 minutes, inspect speed of feed at different levels by random samples simultaneously, record fail-test logout, if inspect out existence by random samples to carry out speed lower than 2% of default speed of feed, or higher than 6% of default speed of feed,, then existing defects is judged; 3. by logistics trolley slide unit respectively with the rapid traverse speed of 500mm/min, 2000mm/min, 3000mm/min, 10000mm/min, 20000mm/min Y-direction full stroke range of motion 5 minutes, inspect speed of feed at different levels by random samples simultaneously, record fail-test logout, if inspect out existence by random samples to carry out speed lower than 2% of default speed of feed, or higher than 6% of default speed of feed,, then existing defects is judged; 4. by logistics trolley slide unit respectively with the rapid traverse speed of 500mm/min, 2000mm/min, 10000mm/min, 20000mm/min, 30000mm/min Z-direction full stroke range of motion 5 minutes, inspect speed of feed at different levels by random samples, record fail-test logout simultaneously; Speed of feed is there is lower than 2% of default speed of feed if inspected by random samples out, or higher than 6% of default speed of feed, then judge existing defects;
As do not judged existing defects in step (1), then carry out following step (2)
(2) load running test procedure: described load running test procedure comprises 1. in X-direction, controls logistics trolley and comes and goes five times between X=0 and X=11500mm with the speed of feed of 50000mm/min, record dolly position coordinates; 2. in the Y direction, logistics trolley comes and goes five times between Y=0 and Y=965mm with the speed of feed of 10000mm/min, record dolly position coordinates; 3. in Z-direction, logistics trolley comes and goes five times between Z=0 and Z=1600mm with the speed of feed of 15000mm/min, record dolly position coordinates; 4. judge according to the data of three directions test the requirement whether logistics trolley positioning precision meets error and be less than 0.25mm; If do not met the demands, then judge existing defects; If met the demands, carry out next step; 5. control logistics trolley and get back to origin position, and by frock clamp, four are heavily got on for the saddle weight device of 500kg is fixed to logistics trolley; 6. logistics trolley is run according to the working procedure of test mission section establishment, set 2 hours automatic working times, namely 0,6000,12000,23,000 four analog machine sites are set in dolly X stroke range, dolly moves to four points successively, total travel back and forth movement is carried out once in Y-direction at each some slide unit, Z-direction half trip round trip, one circulates 62.5 seconds consuming time; 6. step does not have performance index require and only have function to specify, be judged to inefficacy when it cannot complete function action, failure mode comprises following four kinds:
1) logistics trolley is in certain direction of X, Y, Z or simultaneously several directions attonity;
2) the logistics trolley misoperation that postpones in certain direction of X, Y, Z or simultaneously several directions action or shift to an earlier date;
3) logistics trolley certain direction of X, Y, Z or simultaneously several direction exceed range of movement;
4) logistics trolley is in certain direction of X, Y, Z or occur stuck simultaneously;
7. automatically run after two hours, adopt 3 test cycles (namely in step 2 the 6. point) of manually operation task section, and measure the XYZ coordinate of dolly successively, detection repetitive positioning accuracy, whether more than 0.5mm, if exceeded, judges existing defects; 8. repeat step 6. with step content 7., until test closing time T=120h;
As step (2) does not judge existing defects, then proceed following step (3)
(3) aftertreatment is tested: 1) unload saddle weight, lift back storage; 2) logistics trolley cleaned and safeguard.
Detection method of the present invention, draws after carrying out failure mode analysis (FMA) and tub curve quantitative analysis to logistics trolley.The real work situation of this method simulation logistics trolley in flexible manufacturing system, carries out Reliability Enhancement Testing, excites and detect its initial failure.First test method of the present invention carries out speed of feed test, trial run inspection is done to the performance of logistics trolley, to find significantly to assemble defect, carry out strengthening load running test again, namely when carrying out dolly load test, dolly carries its maximum load weight, and move with maximum speed of feed, when motion frequency also substantially exceeds operating mode, detect its positional precision, detect its incipient fault.Carry out after final test dismantling, clean and safeguarding.If break down in each step, can carry out artificial treatment or eliminating, if can not get rid of, this logistics trolley is forbidden dispatching from the factory, if can get rid of, and, then the detection of subsequent step can be proceeded after fixing a breakdown.Logistics trolley after test, if can eliminate defect, then eliminates after defect and can ressemble, load in flexible manufacturing system complete machine, and its logistics trolley that so just can ensure to dispatch from the factory occurs that the probability of initial failure reduces greatly.
In sum, this method is by the mode of test, carry out initial failure to the critical function parts-logistics trolley of flexible manufacturing system logistics system to excite, find the latent defect of manufacturing process or design, thus provide practical approach for improving the reliability of complete machine tool, ensure that the lathe dispatched from the factory occurs that the probability of initial failure reduces greatly.This method can also when designing, whether existing defects provides reference frame, so that improve Machine Tool design for lathe simultaneously.
Embodiment
Below in conjunction with embodiment, the present invention is described in further detail.
It is that logistics trolley in the flexible manufacturing system of FMS80 detects that this method is particularly suitable for model.Specifically, when reliability incipient fault detection is carried out to this material dolly, comprise the following steps,
A kind of flexible manufacturing system logistics trolley incipient fault detection method, comprises the following steps,
(1) speed of feed test procedure: described speed of feed test procedure comprises and being 1. directly mounted in the flexible manufacturing system of test battery by logistics trolley qualified to performance, accuracy test, and debugging its basic function good; Test adopts the mode of logistics trolley independent operating to carry out, therefore require in process of the test, to ensure that the positions such as loading and unloading station, cleaning machine, host tray exchange frame do not have pallet, in order to avoid test causes device damage and personal damage because interfering phenomenon, and the power supply of the system without interaction such as main frame, cleaning machine, loading and unloading station in cutting system in process of the test, ensure can not start in system without interaction process of the test; 2. by logistics trolley respectively with the rapid traverse speed of 1000mm/min, 5000mm/min, 20000mm/min, 60000mm/min, 80000mm/min, 100000mm/min at X to full stroke range of motion 5 minutes, inspect speed of feed at different levels by random samples simultaneously, record fail-test logout, if inspect out existence by random samples to carry out speed lower than 2% of default speed of feed, or higher than 6% of default speed of feed,, then existing defects is judged; 3. by logistics trolley slide unit respectively with the rapid traverse speed of 500mm/min, 2000mm/min, 3000mm/min, 10000mm/min, 20000mm/min Y-direction full stroke range of motion 5 minutes, inspect speed of feed at different levels by random samples simultaneously, record fail-test logout, if inspect out existence by random samples to carry out speed lower than 2% of default speed of feed, or higher than 6% of default speed of feed,, then existing defects is judged; 4. by logistics trolley slide unit respectively with the rapid traverse speed of 500mm/min, 2000mm/min, 10000mm/min, 20000mm/min, 30000mm/min Z-direction full stroke range of motion 5 minutes, inspect speed of feed at different levels by random samples, record fail-test logout simultaneously; Speed of feed is there is lower than 2% of default speed of feed if inspected by random samples out, or higher than 6% of default speed of feed, then judge existing defects;
In above-mentioned steps (1), environmental stress conditions specifically can be set to: test temperature: 10 DEG C ~ 40 DEG C; Temperature variation≤20 DEG C/h; Relative humidity: 10% ~ 15%; Vibration≤0.5G; Test heavy burden load is 0.
As do not judged existing defects in step (1), then carry out following step (2)
(2) load running test procedure: described load running test procedure comprises 1. in X-direction, controls logistics trolley and comes and goes five times between X=0 and X=11500mm with the speed of feed of 50000mm/min, record dolly position coordinates; 2. in the Y direction, logistics trolley comes and goes five times between Y=0 and Y=965mm with the speed of feed of 10000mm/min, record dolly position coordinates; 3. in Z-direction, logistics trolley comes and goes five times between Z=0 and Z=1600mm with the speed of feed of 15000mm/min, record dolly position coordinates; 4. judge according to the data of three directions test the requirement whether logistics trolley positioning precision meets error and be less than 0.25mm; If do not met the demands, then judge existing defects; If met the demands, carry out next step; 5. control logistics trolley and get back to origin position, and by frock clamp, four are heavily got on for the saddle weight device of 500kg is fixed to logistics trolley; 6. logistics trolley is run according to the working procedure of test mission section establishment, set 2 hours automatic working times, namely 0,6000,12000,23,000 four analog machine sites are set in dolly X stroke range, dolly moves to four points successively, total travel back and forth movement is carried out once in Y-direction at each some slide unit, Z-direction half trip round trip, one circulates 62.5 seconds consuming time; 6. step does not have performance index require and only have function to specify, be judged to inefficacy when it cannot complete function action, failure mode comprises following four kinds:
1) logistics trolley is in certain direction of X, Y, Z or simultaneously several directions attonity;
2) the logistics trolley misoperation that postpones in certain direction of X, Y, Z or simultaneously several directions action or shift to an earlier date;
3) logistics trolley certain direction of X, Y, Z or simultaneously several direction exceed range of movement;
4) logistics trolley is in certain direction of X, Y, Z or occur stuck simultaneously;
7. automatically run after two hours, adopt 3 test cycles (namely in step 2 the 6. point) of manually operation task section, and measure the XYZ coordinate of dolly successively, detection repetitive positioning accuracy, whether more than 0.5mm, if exceeded, judges existing defects; 8. repeat step 6. with step content 7., until test closing time T=120h;
In above-mentioned steps (2), environmental stress conditions specifically can be set to: test temperature: 10 DEG C ~ 40 DEG C; Temperature variation≤20 DEG C/h; Relative humidity: 10% ~ 15%; Vibration≤0.5G; Test is born a heavy burden for 500kg.
As step (2) does not judge existing defects, then proceed following step (3)
(3) aftertreatment is tested: 1) unload saddle weight, lift back storage; 2) logistics trolley cleaned and safeguard.
Finally should be noted that above fact Example only for illustration of, and unrestricted implementer's case of the present invention, although with reference to above-described embodiment to invention has been detailed description, those of ordinary skill in the art is to be understood that; Still can modify to the present invention or same replacement, and not depart from any amendment or the local amendment of the spirit and scope of the present invention, it all should be encompassed in protection scope of the present invention.
Claims (1)
1. a flexible manufacturing system logistics trolley incipient fault detection method, comprises the following steps,
(1) speed of feed test procedure: described speed of feed test procedure comprises and being 1. directly mounted in the flexible manufacturing system of test battery by logistics trolley qualified to performance, accuracy test, and debugging its basic function good; Test adopts the mode of logistics trolley independent operating to carry out, therefore require in process of the test, to ensure that the positions such as loading and unloading station, cleaning machine, host tray exchange frame do not have pallet, in order to avoid test causes device damage and personal damage because interfering phenomenon, and the power supply of the system without interaction such as main frame, cleaning machine, loading and unloading station in cutting system in process of the test, ensure can not start in system without interaction process of the test; 2. by logistics trolley respectively with the rapid traverse speed of 1000mm/min, 5000mm/min, 20000mm/min, 60000mm/min, 80000mm/min, 100000mm/min at X to full stroke range of motion 5 minutes, inspect speed of feed at different levels by random samples simultaneously, record fail-test logout, if inspect out existence by random samples to carry out speed lower than 2% of default speed of feed, or higher than 6% of default speed of feed, then judge existing defects; 3. by logistics trolley slide unit respectively with the rapid traverse speed of 500mm/min, 2000mm/min, 3000mm/min, 10000mm/min, 20000mm/min Y-direction full stroke range of motion 5 minutes, inspect speed of feed at different levels by random samples simultaneously, record fail-test logout, if inspect out existence by random samples to carry out speed lower than 2% of default speed of feed, or higher than 6% of default speed of feed, then judge existing defects; 4. by logistics trolley slide unit respectively with the rapid traverse speed of 500mm/min, 2000mm/min, 10000mm/min, 20000mm/min, 30000mm/min Z-direction full stroke range of motion 5 minutes, inspect speed of feed at different levels by random samples, record fail-test logout simultaneously; There is speed of feed lower than 2% of default speed of feed if inspected by random samples out, or higher than 6% of default speed of feed, then judge existing defects;
As do not judged existing defects in step (1), then carry out following step (2)
(2) load running test procedure: described load running test procedure comprises 1. in X-direction, controls logistics trolley and comes and goes five times between X=0 and X=11500mm with the speed of feed of 50000mm/min, record dolly position coordinates; 2. in the Y direction, logistics trolley comes and goes five times between Y=0 and Y=965mm with the speed of feed of 10000mm/min, record dolly position coordinates; 3. in Z-direction, logistics trolley comes and goes five times between Z=0 and Z=1600mm with the speed of feed of 15000mm/min, record dolly position coordinates; 4. judge according to the data of three directions test the requirement whether logistics trolley positioning precision meets error and be less than 0.25mm; If do not met the demands, then judge existing defects; If met the demands, carry out next step; 5. control logistics trolley and get back to origin position, and by frock clamp, four are heavily got on for the saddle weight device of 500kg is fixed to logistics trolley; 6. logistics trolley is run according to the working procedure of test mission section establishment, set 2 hours automatic working times, namely 0,6000,12000,23,000 four analog machine sites are set in dolly X stroke range, dolly moves to four points successively, total travel back and forth movement is carried out once in Y-direction at each some slide unit, Z-direction half trip round trip, one circulates 62.5 seconds consuming time; 6. step does not have performance index require and only have function to specify, be judged to inefficacy when it cannot complete function action, failure mode comprises following four kinds:
1) logistics trolley is in certain direction of X, Y, Z or simultaneously several directions attonity;
2) the logistics trolley misoperation that postpones in certain direction of X, Y, Z or simultaneously several directions action or shift to an earlier date;
3) logistics trolley certain direction of X, Y, Z or simultaneously several direction exceed range of movement;
4) logistics trolley is in certain direction of X, Y, Z or occur stuck simultaneously;
7. automatically run after two hours, adopt 3 test cycles (namely in step 2 the 6. point) of manually operation task section, and measure the XYZ coordinate of dolly successively, detection repetitive positioning accuracy, whether more than 0.5mm, if exceeded, judges existing defects; 8. repeat step 6. with step content 7., until test closing time T=120h;
As step (2) does not judge existing defects, then proceed following step (3)
(3) aftertreatment is tested: 1) unload saddle weight, lift back storage; 2) logistics trolley cleaned and safeguard.
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