CN111069975A - Real-time monitoring and self-adaptive control system and method for terminal running state of numerically controlled milling machine - Google Patents
Real-time monitoring and self-adaptive control system and method for terminal running state of numerically controlled milling machine Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
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Abstract
The invention discloses a real-time monitoring and self-adaptive control system and a control method for the running state of the tail end of a numerical control milling machine, wherein the system comprises a vibration sensor, a data acquisition unit, a data analysis processor, a data storage server and numerical control equipment; the vibration sensor is mounted at the tail end of a main shaft or an angle milling head of the numerical control milling machine and used for monitoring vibration signals of the running state of the tail end of the milling machine in real time, the data analysis processor carries out frequency spectrum transformation analysis processing on the collected vibration data, identifies abnormal information or vibration in the cutting process of the milling machine, stores the processed data in the data storage server, generates a corresponding control instruction according to the identified abnormal information and sends the control instruction to the numerical control equipment so as to implement self-adaptive control. The system can identify the abnormal operation state of the equipment, warn potential risks existing in the terminal cutting process of the milling machine, immediately send control instructions, effectively improve the operation safety of the equipment and reduce the enterprise cost.
Description
Technical Field
The invention belongs to the field of part machining process equipment, and particularly relates to a real-time detection and self-adaptive control system and a control method for the tail end running state of a shell part machined by a numerical control milling machine.
Background
With the rapid development of aerospace technology, more and more high-strength integral structural members are applied to space vehicles such as carrier rockets, satellites and the like. The component is typically characterized by complex structure, high feature integration level, large material removal amount, high cutting precision requirement, and high-end numerical control equipment with high precision and high price must be used for processing to meet the manufacturing requirement of parts.
The maximum cutting efficiency of the numerical control milling machine is mainly determined by the comprehensive actions of the maximum cutting power of the machine tool, the maximum cutting load which can be borne by the machine tool, the maximum cutting load of a cutter, the condition of self-excited vibration of the machine tool and the like, if any link exceeds the load, the whole cutting system is unstable, system faults are caused, and product quality problems and equipment faults are caused seriously. Therefore, in the conventional operation, in order to ensure the product processing quality and reduce the equipment operation risk, the stable operation of the system can be replaced by reducing the cutting parameters at the cost of losing the equipment utilization rate, so that the cutting performance of high-end numerical control equipment and cutters cannot be fully exerted, and the overall utilization rate of the equipment is greatly influenced. In addition, when selecting the operation parameters of the equipment, the process design and the operation personnel mainly rely on personal experience to judge, the parameter difference selected by different personnel is large, some selection is relatively conservative, the performance of the equipment performance and the improvement of the operation efficiency are seriously influenced, some process design and operation personnel can select large cutting parameters in order to keep pace with the schedule, the risk of exceeding the maximum load of a certain link of a process system exists in the operation process, the processing quality of products is further influenced, and the equipment abrasion and even the equipment damage are aggravated. Therefore, it is necessary to research and develop a set of control system which can be used for monitoring the running state of the numerical control equipment in real time, monitoring the running load and vibration condition of the equipment in real time, and evaluating the running state in real time, if the monitoring data is found to be abnormal, an abnormal control instruction is rapidly generated and sent to the numerical control machine, so that the numerical control equipment can be ensured to run stably under higher cutting efficiency.
Disclosure of Invention
Aiming at the problems in the prior art, the invention aims to solve the problems that when a numerical control milling machine adopts a main shaft or an angle milling head to mill parts, if the cutting load is increased due to unreasonable cutting parameter selection or serious cutter abrasion, the whole cutting system is unstable and system faults are caused.
The technical scheme of the invention is as follows: the real-time monitoring and self-adaptive control system of the running state of the tail end of the numerical control milling machine comprises: the system comprises a vibration sensor, a data acquisition unit, a data analysis processor, a data storage server and numerical control equipment; the vibration sensor is arranged at the tail end of a main shaft or an angle milling head of the numerical control milling machine and used for detecting a vibration signal of the running state of the tail end of the milling machine in real time, and the output end of the vibration sensor is connected with the data acquisition unit; the data acquisition unit sends the acquired vibration data to the data analysis processor; the data analysis processor is respectively connected with the data storage server and the numerical control equipment, the data analysis processor carries out truncation, windowing and frequency spectrum transformation processing on the collected vibration data, extracts and analyzes the state information of the equipment in a time domain and a frequency domain respectively, identifies abnormal information in the cutting process of the milling machine, stores the processed data in the data storage server, and simultaneously records the running log of the whole system; the data analysis processor also comprises an adaptive control module, and the adaptive control module can generate a corresponding control instruction according to the identified abnormal information and send the control instruction to the numerical control equipment so as to implement adaptive control.
Furthermore, the vibration sensor is fixedly connected with the tail end of the main shaft or the angle milling head through threads.
Furthermore, the vibration sensor is a three-way acceleration sensor, and the acquisition vibration frequency is 0.01-10 kHz.
Furthermore, the data acquisition unit is matched with the acceleration sensor, adopts a three-channel vibration signal acquisition box, has 24-bit resolution and outputs data by adopting a USB data line.
Further, the data analysis processor is based on an X86 architecture, and a bottom system runs based on a windows platform and comprises two USB ports, two RJ45 network interfaces and 1 serial port supporting RS232 and RS485 communication.
The method for real-time monitoring and self-adaptive control of the running state of the tail end of the numerical control milling machine is realized by the following steps:
(1) calibrating the running state of the numerical control milling machine: installing a vibration sensor at the tail end of a main shaft or an angle milling head, finishing the connection of each part of a real-time monitoring and self-adaptive control system, starting the system, starting a milling machine, recording vibration characteristic signals at different main shaft rotating speeds in a non-cutting state under a normal state, identifying modal parameters under each vibration characteristic, and storing the modal parameters into a data storage server to form a milling machine characteristic knowledge base;
(2) setting a maximum amplitude threshold value and a working mode of the system;
(3) formally starting a system and the numerical control milling machine, wherein a monitoring system acquires the vibration characteristics of the tail end of a machine tool spindle or an angle milling head and the real-time operation parameters of numerical control equipment in real time, compares and analyzes the vibration characteristics and the real-time operation parameters with a calibration value in a frequency domain through frequency spectrum transformation and analysis, identifies the frequency characteristics and the amplitude of a cutter tooth passing frequency and other frequencies in the part machining process, accurately distinguishes the cutting and non-cutting time periods of parts, and accurately monitors the cutting state of the machine tool; if the amplitude of the cutting vibration time domain signal exceeds the maximum amplitude threshold value preset by the system due to unreasonable parameter setting in the cutting process or cutting vibration is induced in the cutting process, the system can quickly generate a control instruction and send the control instruction to the numerically controlled milling machine, and the numerically controlled milling machine adjusts the operation parameters and states according to the control instruction, so that self-adaptive control is realized, and stable operation of equipment is ensured.
Further, the control instruction comprises one or more of a feeding magnification adjusting instruction, an alarm message and a pause command.
Has the advantages that: the invention can monitor the vibration state of the tail end of the main shaft or the angle milling head of the numerical control milling machine in real time, identify the abnormal operation state of the equipment through high-speed processing and analysis of monitoring data, warn the potential risk in the cutting process of the tail end of the milling machine, immediately send a control instruction to the numerical control equipment, effectively improve the operation safety of the equipment and reduce the enterprise cost.
The concrete effects include: 1) the effective cutter cutting and non-cutting time periods of the part are identified with high precision, so that the cutter and the end effector can be managed accurately in a life cycle;
2) the problems of low processing efficiency, poor part processing quality and rapid tool abrasion caused by unreasonable parameter setting in the processing process of aerospace key parts are solved, so that the operation cost of enterprises is greatly reduced, and the enterprise benefit is increased;
3) the change rule of the non-cutter tooth passing frequency amplitude characteristic is monitored in real time, potential fault risks existing in a transmission part of a main shaft or an angle milling head are diagnosed, the end effector is maintained before being completely damaged, the sudden fault shutdown risk of a machine tool is reduced, and the utilization rate of equipment is improved.
Drawings
FIG. 1 is a schematic structural diagram of a real-time monitoring and adaptive control system for the vibration state of the tail end of a numerically controlled milling machine.
In the figure: 1. the system comprises a vibration sensor, 2, a data acquisition unit, 3, a data analysis processor, 4, a numerical control milling machine equipment control system, 5 and a data storage server.
Detailed Description
The present invention will be described in more detail below with reference to the accompanying drawings.
As shown in fig. 1, the system is a schematic structural diagram of a system for real-time monitoring and adaptive control of vibration information of a numerically controlled milling machine in an operating state, and mainly includes four parts, a vibration sensor 1, a data acquisition unit 2, a data analysis processor 3, a data storage server 5, and a numerically controlled milling machine equipment control system 4.
The vibration sensor 1 adopts a three-way acceleration sensor, the acquisition frequency is 0.01-10KHz, and the vibration sensor is used for acquiring vibration signals of the machine tool in the cutting process. The vibration sensor can be installed at the tail end of the main shaft or the angle milling head in a threaded mode and is as close to the rotary cutter as possible, so that vibration signals of the operation of the main shaft and the cutting process of the cutter can be collected more clearly. For some shell section products, an angle milling head needs to be additionally arranged at a main shaft end of a machine tool, then the angle milling head extends into a shell section to be machined into an inner shape, and for the type of working condition, a vibration sensor needs to be additionally arranged at the tail end of the angle milling head to acquire a three-way vibration signal at the tail end of the angle milling head in real time.
The data acquisition unit 2 is used in cooperation with the acceleration sensor, selects a three-channel vibration signal acquisition box, has 24-bit resolution and adopts a USB data line for output.
The data analysis processor 3 is used for carrying out processing and analysis work on the collected data, the processor is based on an X86 architecture, a bottom layer system runs based on a windows platform, and the processor comprises two USB ports (one is used for connecting the data collector 2, and the other is used for connecting debugging equipment); and one of the two RJ45 network interfaces is used for connecting with a control system 4 of the numerically controlled milling machine equipment, and the other one is used for communicating with a background data storage server 5, and the RJ45 network interfaces also comprise 1 serial port supporting RS232 and RS 485.
The data storage server 5 is used for storing the data processed by the analysis processor 3 and simultaneously recording the running log of the whole system. The most core of the system is a data analysis processor which can intercept, window and frequency spectrum transform the collected time domain vibration signals, extract and analyze the state information of the equipment in time domain and frequency domain respectively, identify the abnormal information of the machine tool in the cutting process and further implement self-adaptive control.
When the device is used, the vibration sensor is firstly installed at the tail end of the main shaft or the angle milling head, and the real-time monitoring and self-adaptive control system is connected; before the system runs, the running state of the numerical control machine tool needs to be calibrated, the monitoring system is started, the machine tool is started, vibration signals of the numerical control machine tool in a normal state and in a non-cutting state are recorded, the process needs to run the rotating speeds of the main shaft used for processing products at ordinary times step by step once respectively, and the vibration characteristics of the tail end of the main shaft in different rotating speeds are recorded respectively; secondly, identifying modal parameters under various vibration characteristics, including main excitation frequency and resonance frequency of the machine tool, modal mass, rigidity, damping and the like of the machine tool; and finally, inputting all the parameters into a data storage server for storage to form a corresponding machine tool characteristic knowledge base.
After the running state of the numerical control machine is calibrated, a maximum amplitude threshold value needs to be set in the system, and the maximum amplitude threshold value is used for setting the maximum load allowing the numerical control machine and the whole process cutting system to cut. Besides, the system can be set to work continuously or start monitoring at regular time, and the monitoring is stopped automatically after a period of time, so that the running loss and energy consumption of the equipment are reduced. After the setting is finished, the monitoring system and the numerical control machine tool can be started formally, the monitoring system identifies an idle feed program section and a real material removal section by comparing and analyzing the vibration signal with a calibration value in a frequency domain, and the cutting state of the machine tool is monitored accurately. In the cutting process of the machine tool, if the cutting parameters are set unreasonably, the amplitude of the monitored cutting vibration time domain signal exceeds a system preset threshold value, a self-adaptive control module in the data analysis processor generates a machine tool control instruction to be sent to a machine tool numerical control system, the feeding multiplying power of the machine tool is reduced moderately, and then the running state of the machine tool is interfered, wherein the control instruction can comprise a feeding multiplying power adjusting instruction, or alarm information and a pause command.
In the numerical control machining process of typical aerospace parts, the dynamic cutting thickness of the cutter teeth can cause the fluctuation of cutting force to cause self-excited vibration of a cutting system, if the self-excited vibration does not intervene in time, cutting chatter vibration is caused between a cutter and a weak-rigidity workpiece, the abrasion of a transmission part and the cutter of a machine tool is aggravated, the machining quality of parts is reduced, and the enterprise cost is increased. The data analysis processor monitors the resonant frequency of the cutting system in real time in a frequency domain, except the passing frequency of the cutter teeth (the rotating speed of a main shaft is multiplied by the number of the cutter teeth), if amplitude frequency information with vibration amplitude larger than the passing frequency of the cutter teeth appears in a high-frequency band except the frequency in a calibration parameter, the cutting chatter vibration is induced by the cutting system due to unreasonable parameter selection, the cutting chatter marks on the surface of a part are obvious, the data analysis processor calls an adaptive control module to generate a system interference instruction, the feeding multiplying power of a machine tool is reduced appropriately, the running state of the machine tool is adjusted, and the control instruction can comprise a feeding multiplying power adjusting instruction, or alarm information and a pause instruction.
The invention can acquire the vibration characteristic of the tail end of a main shaft or an angle milling head and the real-time operation parameter of a numerical control system in real time, and identify the frequency characteristic and amplitude of the passing frequency of a cutter tooth and other frequencies in the processing process of a part through frequency spectrum transformation and analysis, accurately distinguish the cutting time period and the non-cutting time period of the part, if the cutting load exceeds the preset maximum threshold value of the system due to unreasonable parameter setting in the cutting process or the cutting vibration of the processing system is induced in the cutting process, the system can quickly generate a machine tool control instruction in a shorter time period and send the machine tool control instruction to the numerical control system, adjust the operation parameter and the state of the machine tool, and ensure the stable operation of.
Claims (7)
1. The real-time monitoring and self-adaptive control system for the running state of the tail end of the numerically controlled milling machine is characterized in that: the system comprises a vibration sensor, a data acquisition unit, a data analysis processor, a data storage server and numerical control equipment; the vibration sensor is arranged at the tail end of a main shaft or an angle milling head of the numerical control milling machine and used for detecting a vibration signal of the running state of the tail end of the milling machine in real time, and the output end of the vibration sensor is connected with the data acquisition unit; the data acquisition unit sends the acquired vibration data to the data analysis processor; the data analysis processor is respectively connected with the data storage server and the numerical control equipment, the data analysis processor carries out truncation, windowing and frequency spectrum transformation processing on the collected vibration data, extracts and analyzes the state information of the equipment in a time domain and a frequency domain respectively, identifies abnormal information in the cutting process of the milling machine, stores the processed data in the data storage server, and simultaneously records the running log of the whole system; the data analysis processor also comprises an adaptive control module, and the adaptive control module can generate a corresponding control instruction according to the identified abnormal information and send the control instruction to the numerical control equipment so as to implement adaptive control.
2. The numerically controlled milling machine end operation state real-time monitoring and adaptive control system according to claim 1, characterized in that: the vibration sensor is fixedly connected with the tail end of the main shaft or the angle milling head through threads.
3. The numerically controlled milling machine end operation state real-time monitoring and adaptive control system according to claim 1, characterized in that: the vibration sensor is a three-way acceleration sensor, and the acquisition vibration frequency is 0.01-10 kHz.
4. The numerically controlled milling machine end operation state real-time monitoring and adaptive control system according to claim 3, characterized in that: the data acquisition unit is matched with the acceleration sensor, adopts a three-channel vibration signal acquisition box, has 24-bit resolution and outputs data by adopting a USB data line.
5. The numerically controlled milling machine end operation state real-time monitoring and adaptive control system according to claim 1, characterized in that: the data analysis processor is based on an X86 framework, a bottom layer system runs based on a windows platform and comprises two USB ports, two RJ45 network interfaces and 1 serial port supporting RS232 and RS485 communication.
6. The real-time monitoring and self-adaptive control method for the running state of the tail end of the numerical control milling machine is characterized by comprising the following steps of: the method is realized by the following steps:
(1) calibrating the running state of the numerical control milling machine: installing a vibration sensor at the tail end of a main shaft or an angle milling head, finishing the connection of each part of a real-time monitoring and self-adaptive control system, starting the system, starting a milling machine, recording vibration characteristic signals at different main shaft rotating speeds in a non-cutting state under a normal state, identifying modal parameters under each vibration characteristic, and storing the modal parameters into a data storage server to form a milling machine characteristic knowledge base;
(2) setting a maximum amplitude threshold value and a working mode of the system;
(3) formally starting a system and the numerical control milling machine, wherein a monitoring system acquires the vibration characteristics of the tail end of a machine tool spindle or an angle milling head and the real-time operation parameters of numerical control equipment in real time, compares and analyzes the vibration characteristics and the real-time operation parameters with a calibration value in a frequency domain through frequency spectrum transformation and analysis, identifies the frequency characteristics and the amplitude of a cutter tooth passing frequency and other frequencies in the part machining process, accurately distinguishes the cutting and non-cutting time periods of parts, and accurately monitors the cutting state of the machine tool; if the amplitude of the cutting vibration time domain signal exceeds the maximum amplitude threshold value preset by the system due to unreasonable parameter setting in the cutting process or cutting vibration is induced in the cutting process, the system can quickly generate a control instruction and send the control instruction to the numerically controlled milling machine, and the numerically controlled milling machine adjusts the operation parameters and states according to the control instruction, so that self-adaptive control is realized, and stable operation of equipment is ensured.
7. The numerically controlled milling machine end operation state real-time monitoring and self-adaptive control method according to claim 6, characterized in that: the control instruction comprises one or more of a feeding magnification adjusting instruction, alarm information and a pause command.
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| CN111580457A (en) * | 2020-05-08 | 2020-08-25 | 新代科技(苏州)有限公司 | Method for inhibiting machining oscillation lines of numerical control machine tool by using acceleration gauge |
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| CN113059402A (en) * | 2021-03-31 | 2021-07-02 | 南昌大学 | Milling flutter intelligent monitoring system of numerically controlled milling machine |
| CN114083347A (en) * | 2021-12-06 | 2022-02-25 | 意特利（上海）科技有限公司 | Five-axis linkage numerical control machine tool monitoring method and system |
| CN114326589A (en) * | 2021-12-17 | 2022-04-12 | 上海电气集团股份有限公司 | Monitoring method, device and system |
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| CN117798390A (en) * | 2023-12-29 | 2024-04-02 | 新昌合旸汽车零部件有限公司 | Automatic production device for automobile bearings |
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