CN113977348B - Machine tool whole-course self-sensing self-adaptive cutting method - Google Patents
Machine tool whole-course self-sensing self-adaptive cutting method 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
- B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
- B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
- B23Q15/12—Adaptive control, i.e. adjusting itself to have a performance which is optimum according to a preassigned criterion
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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
- B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
- B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
- B23Q15/013—Control or regulation of feed movement
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Abstract
The invention relates to a machine tool whole-course self-sensing self-adaptive cutting method, belonging to the technical field of machining centers, comprising a main shaft motor output load rate calculator configured by a machine tool numerical control system, a PMC programmable controller and a related parameter setting human-computer interface, wherein the actual feeding speed of a machine tool = program feeding speed value x feeding multiplying power is determined, the main shaft motor output load rate and the change amplitude thereof are sensed and detected in real time through a PMC program, the machine tool feeding cutting multiplying power value is self-adaptively changed and adjusted through software algorithm and control, the self-adaptive cutting of the machine tool feeding speed is controlled, and the main shaft motor output load rate data in the machining process can be monitored in real time through the numerical control system. The method has the characteristics of good operation stability, long service life of the cutter and high processing efficiency. The problems of machine tool vibration and insufficient cutting process efficiency in the heavy cutting process are solved.
Description
Technical Field
The invention relates to the technical field of machining centers, in particular to a machine tool whole-course self-sensing self-adaptive cutting method.
Background
The machining center is the most important equipment on a flexible machining production line. At present, a large number of horizontal machining centers are used in a plurality of production lines, such as the production line of cylinder bodies and cylinder covers of automobile engines. But the reliability level of many horizontal machining centers is still relatively low at present. The low reliability level of the horizontal machining center can directly influence the production efficiency of users of the horizontal machining center.
The machining center has the following defects in the feeding and cutting process: 1) when the heavy cutting process enters a cutter initial section, the load of a main shaft is increased instantaneously, and the cutting vibration of a machine tool is large; 2) when the end point section of the cutter is discharged in the heavy cutting process, the load of the main shaft is instantaneously reduced, and the cutting vibration of the machine tool is large; 3) in the heavy cutting process, the service life of the cutter is short; 4) the effect of the spindle motor cannot be fully exerted in the full-cutting process, high-speed feeding is realized, and the machining efficiency is low.
The chinese patent "method for adaptive feed cutting in machining center", application No. 201911112993.0, describes the feed cutting process in machining center, only relates to the process of the tool-in section and the tool-out section, and lacks the improvement of the process when the middle section of the machining center is machined to full-length cutting.
Disclosure of Invention
The invention mainly solves the defects of large vibration of a heavy cutting feed section and a heavy cutting discharge section, short service life of a cutter and low processing efficiency of a full-cutter cutting section in the prior art, and provides a machine tool whole-course self-sensing self-adaptive cutting method which has the characteristics of good operation stability, long service life of the cutter and high processing efficiency. The problems of machine tool vibration and insufficient cutting process efficiency in the heavy cutting process are solved. The self-adaptive cutting method has the advantages that the feeding speed of the cutting feed-in section and the cutting discharge section is reduced, so that the purpose of reducing the vibration of a machine tool is achieved, in the full cutting process, when the spindle is sensed to be low in load, the machine tool is switched to be high-speed feeding, and when the spindle is sensed to be high in load, the machine tool is switched to be low-speed feeding.
The technical problem of the invention is mainly solved by the following technical scheme:
a whole-course self-sensing self-adaptive cutting method of a machine tool comprises a main shaft motor output load rate calculator configured by a machine tool numerical control system, a PMC programmable controller and related parameters are provided with a human-computer interface, the actual feed speed of the machine tool = program feed speed value multiplied by feed multiplying factor is determined, the main shaft motor output load rate and the change amplitude thereof are sensed and detected in real time through a PMC program, the machine tool feed cutting multiplying factor value is adaptively changed and adjusted through software algorithm and control, the self-adaptive cutting of the machine tool feed speed is controlled, and the main shaft motor output load rate data in the machining process can be monitored in real time through the numerical control system; reading a spindle motor output load rate value and calculating a load rate change fluctuation data value through a programmable controller PMC software program in a real-time self-sensing manner, calculating a spindle motor load rate change fluctuation value through a machine tool machining heavy-entry cutter section PMC self-sensing detection, automatically reducing a feed cutting multiplying power to a cutter entry section self-adaptive initial feed multiplying power E when a cutter entry section spindle load change threshold value A is exceeded, and automatically gradually increasing the feed cutting multiplying power to restore the standard value to 100% in a set time D; PMC self-perception detects the load rate data value of the spindle motor in the full cutting process of machine tool machining, when exceeding the upper limit value H of the spindle load, the automatic adjustment is gradually decreased at intervals of 10% multiplying power value, and the multiplying power adjustment is stopped until the load rate of the spindle motor is lower than H; when the load rate of the spindle motor is lower than a spindle load reference value J, automatically adjusting the spindle motor to gradually increase at intervals of 10% of multiplying power values until the maximum value K of the self-adaptive feed cutting multiplying power is reached and then stopping multiplying power adjustment; the PMC self-perception detection main shaft motor load rate change fluctuation of the cutter outlet section is achieved, when the load rate is lower than a cutter outlet section main shaft load change threshold B, the feed cutting multiplying power is automatically reduced to the cutter outlet section self-adaptive initial feed multiplying power F, and the feed cutting multiplying power is automatically and gradually increased to be restored to a standard value of 100% step by step within set time D.
Preferably, the PMC program self-perception detection and algorithm are used for obtaining spindle load rate data and calculating fluctuation data, and the feed cutting rate values of the cutter entering section, the full cutting process and the cutter discharging section are automatically controlled and adjusted:
entering a cutter section: in a set period of a data register C value of main shaft load change acquisition time, PMC acquires, stores and senses a register value of actually measured main shaft motor load rate data at intervals, differential subtraction operation is carried out on load rates before and after the set period of acquisition time, an operation result value is input blade section main shaft motor load rate fluctuation data, and an operation formula is as follows: and the result value = main shaft load rate value after the acquisition time C-main shaft load rate value before the acquisition time C, when the operation result value is greater than the set threshold value A, starting adaptive feed control, modifying the assigned value data of the feed cutting multiplying factor register by the PMC to reduce the feed cutting multiplying factor to a set value E, completing an automatic adjustment control method of stepwise increasing the feed cutting multiplying factor within the set time D, gradually recovering the feed cutting multiplying factor to 100%, and finishing the adaptive control of the tool entering section.
Full-cutter cutting section: the PMC detects and acquires a current spindle motor output load rate data register value in a self-sensing mode in real time, when the current spindle load rate exceeds a set upper limit threshold value H, self-adaptive feed control is started, the PMC modifies a rate value at intervals and decreases at a speed of 10%, and whether the spindle load rate exceeds the threshold value H or not is recalculated and compared every time until the spindle load rate is lower than the threshold value H, and the self-adaptive feed control is stopped.
Full-cutter cutting section: the PMC detects and collects a current spindle motor output load rate data register value in a self-sensing mode in real time, when the current spindle load rate is lower than a set load reference value J, self-adaptive feed control is started, the PMC modifies a rate value at intervals and increases the rate at a speed of 10%, the spindle load rate is recalculated and compared every time, the feed rate is gradually increased along with the increase of the feed rate, the spindle load is gradually increased along with the increase of the feed rate, and the self-adaptive feed control is stopped until the spindle load rate is higher than the reference value J; increasing the maximum value K of the self-adaptive multiplying power, and in the process of gradually increasing the feed cutting multiplying power and gradually increasing the load rate of the main shaft, adaptively adjusting the maximum multiplying power value not to exceed the value K; and when the adjusting rate value reaches K, stopping the self-adaptive control.
A cutter discharging section: in a set period of a data register C value of main shaft load change acquisition time, the PMC collects and stores register values of actually measured sensing main shaft motor load rate data at intervals, differential subtraction operation is carried out on load rates before and after the set period of acquisition time, and an operation result value is input section main shaft motor load rate fluctuation data; the operational formula is as follows: and the result value = main shaft load rate value after the acquisition time C-main shaft load rate value before the acquisition time C, when the operation result value is smaller than a set threshold value B, starting adaptive feed control, modifying the assigned data of the feed cutting multiplying factor register by the PMC to reduce the feed cutting multiplying factor to a set value F, finishing an automatic adjustment control method of stepwise increasing the feed cutting multiplying factor within a set time D, gradually recovering the feed cutting multiplying factor to 100%, and finishing the adaptive control of a tool discharging section.
Preferably, the tool entering section spindle load change threshold A is a PMC data register corresponding to A, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the value A is within an allowable range of 0-50%/ms.
Preferably, the tool output section spindle load change threshold B is a PMC data register correspondingly, a corresponding input window is arranged on a system interface, and the parameter setting value of the value B is within an allowable range of 0 to-50%/ms.
Preferably, the load change acquisition time C of the tool entering and exiting is a PMC data register corresponding to the load change acquisition time C, a corresponding input window is arranged on a system interface, and the parameter setting data allowable range of the value C is 4-10 ms.
Preferably, the maintenance time D of the adaptive state of the tool entering and exiting is a PMC data register corresponding to D, a corresponding input window is arranged on a system interface, and the parameter setting numerical value allowable range of the D value is 2-6 s.
Preferably, the feed cutting multiplying power stepped control method indicates that the cutter section self-adaptive initial feed cutting multiplying power E value is subjected to stepped incremental assignment by modifying feed cutting multiplying power data register data through the PMC according to interval time, a corresponding input window is arranged on a system functional interface, and the parameter setting numerical value of the E value is within a range of 10-50%.
Preferably, the feed cutting multiplying power stepped control method indicates that the cutter section self-adaptive initial feed cutting multiplying power F value is subjected to stepped incremental assignment by modifying feed cutting multiplying power data register data through the PMC according to interval time, a corresponding input window is arranged on a system functional interface, and the parameter setting numerical value allowable range of the F value is 10-40%.
Preferably, the main shaft load upper limit value H corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the H value is within an allowable range of 0-150%; in the full cutting process, sensing and detecting that the spindle load rate is larger than an upper limit value H, if the state is kept for a fixed time, triggering adaptive control, and gradually reducing and assigning the PMC at an interval time modification multiplying power at a speed of 10% until the current spindle load rate is smaller than the upper limit value H, and stopping adaptive feed adjustment.
Preferably, the upper limit value J of the spindle load corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the J value is within an allowable range of 0-130%; in the full cutting process, sensing and detecting that the load rate of a spindle is smaller than a reference value J, if the state is kept for a fixed time, triggering adaptive control, modifying feed cutting multiplying power by interval time by a PMC (physical control center) and carrying out incremental assignment at a speed of 10 percent to ensure that the load rate of the spindle gradually approaches the reference value J, and stopping adaptive feed adjustment when the load rate of the spindle is larger than J; and (4) adjusting the self-adaptive feed cutting multiplying power to increase the maximum value K, and stopping the self-adaptive adjustment after the K value is reached.
The invention can achieve the following effects:
compared with the prior art, the invention provides a machine tool whole-course self-sensing self-adaptive cutting method which has the characteristics of good operation stability, long service life of a cutter and high processing efficiency. The problems of machine tool vibration and insufficient cutting process efficiency in the heavy cutting process are solved. The self-adaptive cutting method has the advantages that the feeding speed of the cutting feed-in section and the cutting discharge section is reduced, so that the purpose of reducing the vibration of a machine tool is achieved, in the full cutting process, when the spindle is sensed to be low in load, the machine tool is switched to be high-speed feeding, and when the spindle is sensed to be high in load, the machine tool is switched to be low-speed feeding.
Detailed Description
The technical scheme of the invention is further specifically described by the following embodiments.
A whole-course self-sensing self-adaptive cutting method of a machine tool comprises a main shaft motor output load rate calculator configured by a machine tool numerical control system, a PMC programmable controller and related parameters are provided with a human-computer interface, the actual feed speed of the machine tool = program feed speed value multiplied by feed multiplying factor is determined, the main shaft motor output load rate and the change amplitude thereof are sensed and detected in real time through a PMC program, the machine tool feed cutting multiplying factor value is adaptively changed and adjusted through software algorithm and control, the self-adaptive cutting of the machine tool feed speed is controlled, and the main shaft motor output load rate data in the machining process can be monitored in real time through the numerical control system; the method comprises the steps that a PMC software program reads a spindle motor output load rate value and a calculated load rate change fluctuation data value in a real-time self-sensing mode through a programmable controller PMC software program, the PMC self-sensing detection of a machine tool machining re-cutting-in tool section is used for calculating the spindle motor load rate change fluctuation value, when the spindle load change threshold value A of the cutting-in tool section is exceeded, the spindle load change threshold value A of the cutting-in tool section corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting value of the value A is within a numerical value allowable range of 0-50%/ms. The method comprises the steps of automatically reducing the feed cutting multiplying power to the self-adaptive initial feed multiplying power E of a cutter entering section, wherein the feed cutting multiplying power stepped control method means that the self-adaptive initial feed cutting multiplying power E value of the cutter entering section is subjected to stepped incremental assignment by modifying feed cutting multiplying power data register data through a PMC at fixed 2-second intervals, a corresponding input window is arranged on a system functional interface, and the parameter setting numerical value allowable range of the E value is 10-50%. And in a set time D, keeping time D of the self-adaptive state of the tool entering and exiting, wherein D corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the D value is within an allowable range of 2-6 s. The feed cutting multiplying power is automatically and gradually increased to be restored to the standard value of 100 percent in a step-by-step mode; PMC self-perception detects the load rate data value of the spindle motor in the full cutting process of machine tool machining, when exceeding the upper limit value H of the spindle load, the automatic adjustment is gradually decreased at intervals of 10% multiplying power value, and the multiplying power adjustment is stopped until the load rate of the spindle motor is lower than H; the main shaft load upper limit value H corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the H value is within an allowable range of 0-150%; in the full cutting process, sensing and detecting that the spindle load rate is larger than an upper limit value H, if the state is kept for a fixed time, triggering adaptive control, modifying the feed cutting multiplying power by interval time by the PMC, and gradually reducing and assigning at a speed of 10% until the current spindle load rate is smaller than the upper limit value H, and stopping adaptive feed adjustment. When the load rate of the spindle motor is lower than a spindle load reference value J, automatically adjusting the spindle motor to gradually increase at intervals of 10% of multiplying power values until the maximum value K of the self-adaptive feed cutting multiplying power is reached and then stopping multiplying power adjustment; the main shaft load upper limit value J corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the J value is in an allowable range of 0-130%; in the full cutting process, sensing and detecting that the load rate of a spindle is smaller than a reference value J, if the state is kept for a fixed time, triggering adaptive control, modifying feed cutting multiplying power by interval time by a PMC (physical control center) and carrying out incremental assignment at a speed of 10 percent to ensure that the load rate of the spindle gradually approaches the reference value J, and stopping adaptive feed adjustment when the load rate of the spindle is larger than J; and (4) adjusting the self-adaptive feed cutting multiplying power to increase the maximum value K, and stopping the self-adaptive adjustment after the K value is reached. The PMC self-perception detection main shaft motor load rate change fluctuation of the cutter output section, when the load rate is lower than a cutter output section main shaft load change threshold B, the cutter output section main shaft load change threshold B is correspondingly a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting value of the value B is within an allowable range of 0 to 50%/ms. The method comprises the steps of automatically reducing the feed cutting multiplying power to the self-adaptive initial feed multiplying power F of a cutter outlet section, wherein the feed cutting multiplying power stepped control method indicates that the self-adaptive initial feed cutting multiplying power F of the cutter outlet section is subjected to stepped incremental assignment by modifying feed cutting multiplying power data register data through a PMC at fixed 2-second intervals, a corresponding input window is arranged on a system functional interface, and the parameter setting numerical value allowable range of the F value is 10-40%. And in the set time D, the feed cutting multiplying power is automatically and gradually increased to be recovered to the standard value of 100 percent in a step-by-step mode.
The machine tool numerical control system is provided with a main shaft motor output load rate calculator, and a PMC programmable controller and a human-computer interface for setting the function configuration parameters are embedded in the main shaft motor output load rate calculator. The feeding moving speed of the machine tool is set by a processing program, the actual feeding speed is determined by a program feeding speed value multiplied by a feeding multiplying factor, and the feeding multiplying factor assignment is automatically adjusted and changed through PMC program control and algorithm control, so that the purpose of reducing the feeding speed of cutting in and out sections is realized, and the purpose of reducing the vibration of the machine tool is achieved; in the full cutting process, when the low load of the spindle is sensed, the machine tool is switched into high-speed feeding, and when the high load of the spindle is sensed, the machine tool is switched into low-speed feeding self-adaptive cutting. The fluctuation data of the load rate of the spindle motor in the machining process can be monitored in real time through a numerical control system. And a user-defined program instruction code is additionally arranged, so that the self-adaptive cutting function can be flexibly started and closed according to the actual machining requirement of a user.
Through PMC program self-perception detection and algorithm, main shaft load rate data and calculation fluctuation data are obtained, and feed cutting multiplying power values of a cutter entering section, a full cutting process and a cutter discharging section are automatically controlled and adjusted:
entering a cutter section: and setting a value period C of a data register C of the load change acquisition time of the spindle, wherein the C corresponds to the PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting data allowable range of the value C is 4-10 ms. PMC interval collection storage perception actual measurement spindle motor load factor data register value will set for the load factor before and after the collection cycle time and carry out the difference subtraction operation, and the operation result value is the income sword section spindle motor load factor fluctuation data, operation formula: the result value = main shaft load rate value after the acquisition time C-main shaft load rate value before the acquisition time C, when the operation result value is greater than the set threshold value A, the self-adaptive feed control is started, the PMC modifies the assigned data of the feed cutting multiplying factor register, so that the feed cutting multiplying factor is reduced to the set value E, the automatic adjustment control method of the feed cutting multiplying factor stepwise increment is completed within the set time D, the feed cutting multiplying factor is gradually restored to 100%, and the self-adaptive control of the tool entering section is finished;
full-cutter cutting section: the PMC detects and acquires a register value of the current spindle motor output load rate data in a self-sensing mode in real time, when the current spindle load rate exceeds a set upper limit threshold value H, self-adaptive feed control is started, the PMC modifies a rate value at intervals and decreases at a speed of 10%, and the PMC recalculates and compares whether the spindle load rate exceeds the threshold value H or not every time until the spindle load rate is lower than the threshold value H, and self-adaptive control is stopped;
full-cutter cutting section: the PMC detects and collects a current spindle motor output load rate data register value in a self-sensing mode in real time, when the current spindle load rate is lower than a set load reference value J, self-adaptive feed control is started, the PMC modifies a rate value at intervals and increases the rate at a speed of 10%, the spindle load rate is recalculated and compared every time, the feed rate is gradually increased along with the increase of the feed rate, the spindle load is gradually increased along with the increase of the feed rate, and the self-adaptive feed control is stopped until the spindle load rate is higher than the reference value J; increasing the maximum value K of the self-adaptive multiplying power, and in the process of gradually increasing the feed cutting multiplying power and gradually increasing the load rate of the main shaft, adaptively adjusting the maximum multiplying power value not to exceed the value K;
a cutter discharging section: in a set period of a data register C value of main shaft load change acquisition time, the PMC collects and stores register values of actually measured sensing main shaft motor load rate data at intervals, differential subtraction operation is carried out on load rates before and after the set period of acquisition time, and an operation result value is input section main shaft motor load rate fluctuation data; the operational formula is as follows: and the result value = main shaft load rate value after the acquisition time C-main shaft load rate value before the acquisition time C, when the operation result value is smaller than a set threshold value B, starting adaptive feed control, modifying the assigned data of the feed cutting multiplying factor register by the PMC to reduce the feed cutting multiplying factor to a set value F, finishing an automatic adjustment control method of stepwise increasing the feed cutting multiplying factor within a set time D, gradually recovering the feed cutting multiplying factor to 100%, and finishing the adaptive control of a tool discharging section.
During self-perception self-adaption feeding cutter machining, a PMC program collects a set value of a time period C according to the change of loads of a cutter to be fed and a cutter to be fed, initially recommends and sets 4ms, adjusts according to needs, and continuously stores a register value of spindle motor load rate data measured in a perception mode, and a difference value algorithm formula of spindle load rate fluctuation: the result value = main shaft load value after acquisition period C — main shaft load value before acquisition period C. Through data statistical analysis, a spindle motor load rate fluctuation detection range value in a cutter entering period is set, a spindle load change threshold value A in the cutter entering period is set, 15%/ms is initially recommended and set, and adjustment is carried out as required. When the machine tool heavy cutting cutter entering starting point starts, when a PMC program algorithm calculates that a spindle load fluctuation value is larger than a set spindle load change threshold value A, intelligent self-adaptation of the machine tool can immediately react, a feed cutting multiplying factor value is automatically reduced to a cutter entering section self-adaptation initial feed multiplying factor E value, the initial recommended setting is 40%, and adjustment is carried out as required. After the machine tool adaptive feeding is triggered and started, the feeding speed multiplying power value is operated to realize automatic step-type fixed time period 2s incremental control, the holding time D of the adaptive state of the in-out cutter is set, the initial recommended setting is 5s, the adjustment is carried out as required, and the step-feed cutting multiplying power assignment switching of 40% → 60% → 80% → 100% is completed in the control. Along with the reduction of the speed when the cutter is inserted, the vibration of the machine tool is greatly reduced. The load rate fluctuation of the spindle motor gradually tends to be stable when the cutter is inserted into the cutting section, the self-adaptive adjustment of the feeding speed is changed from slow to fast, the vibration problem of the cutter-inserting machine tool is solved, and the machining efficiency is guaranteed to be slightly influenced.
When the self-inductance value self-adaptive feeding full-cutter machining is carried out, a PMC program senses and detects a spindle motor load data value in real time, a comparison algorithm is used for judging whether the spindle load data value exceeds a spindle load upper limit value H or not, 130% is initially recommended and set, adjustment is carried out as required, when the current spindle load is larger than the H value, self-adaptive feeding of a machine tool is triggered and started, the PMC modifies the feeding cutting multiplying power to be decreased at the speed of 10% within a fixed interval time period of 1s, and when the spindle load is smaller than the H value, self-adaptive feeding adjustment is closed. The control method can effectively protect the normal reasonable standard operation processing of the spindle motor, and avoid the damage to the cutter, the spindle and the machine tool caused by the overload of the spindle cutting process due to the unreasonable programming of the user program processing technology.
When the self-inductance value self-adaptive feeding full-cutter machining is carried out, a PMC program senses and detects a spindle motor load data value in real time, a comparison algorithm is used for judging whether the data value is smaller than a spindle load upper limit value J or not, the initial recommended setting is 120%, the data value is adjusted according to needs, when the current spindle load is smaller than the J value, the self-adaptive feeding of the machine tool is triggered to start, the PMC modifies the feeding cutting multiplying power to increase at the speed of 10% in a fixed interval time period of 2s, the spindle load is increased along with the gradual increase of the feeding speed, and when the spindle load is larger than the J value, the self-adaptive feeding adjustment is closed. The maximum incremental magnification adjustment value does not exceed the maximum adaptive feed magnification value K, the initial recommended setting is 140%, adjustment is carried out as required, and when the incremental magnification value reaches the value K, the adaptive feed adjustment is closed. The control method can effectively exert the output cutting capability of the spindle motor to the maximum extent, avoid the situation that the maximum cutting capability of the machine tool cannot be reasonably exerted due to unreasonable programming of a user program machining process, and greatly improve the machining efficiency.
During self-perception self-adaptation feeding and tool discharging machining, a PMC program initially recommends and sets for 4ms according to a set value of a time period C for acquiring the change of tool feeding and tool discharging load, and the PMC program is adjusted as required to continuously store and perceive a data value of actually measured spindle motor load rate and a difference algorithm formula of spindle load rate fluctuation: the result value = main shaft load value after acquisition period C — main shaft load value before acquisition period C. Through data statistical analysis, a spindle motor load rate fluctuation detection range value in a cutter-out period is set, a spindle load change threshold value B in the cutter-out period is set, initial recommendation is set to be-10%/ms, and adjustment is carried out as required. When the machine tool heavy cutting tool-out starting point starts, when a PMC program algorithm calculates that a spindle load fluctuation value is smaller than a set spindle load change threshold value B, intelligent self-adaptation of the machine tool can immediately react, a feed cutting magnification value is automatically reduced and is limited to a self-adaptive initial feed magnification F of a tool entering section, the initial recommended setting is 30%, and adjustment is carried out as required. After the machine tool adaptive feeding is triggered and started, the feeding speed multiplying power value is operated to realize automatic step-type fixed time period 2s incremental control, the holding time D of the adaptive state of the in-out cutter is set, the initial recommended setting is 5s, the adjustment is carried out as required, and the step-feed cutting multiplying power assignment switching of 30% → 60% → 90% → 100% is completed in the control. Along with the reduction of the speed during the cutter discharging, the vibration of the machine tool is greatly reduced. Along with the continuous deepening of the cutter-discharging distance, the self-adaptive adjustment of the feeding speed is changed from slow to fast, so that the vibration problem of the cutter-discharging machine tool is solved, and the machining efficiency is guaranteed to be slightly influenced.
In conclusion, the whole-course self-sensing self-adaptive cutting method for the machine tool has the characteristics of good operation stability, long service life of the cutter and high machining efficiency. The problems of machine tool vibration and insufficient cutting process efficiency in the heavy cutting process are solved. The self-adaptive cutting method has the advantages that the feeding speed of the cutting feed-in section and the cutting discharge section is reduced, so that the purpose of reducing the vibration of a machine tool is achieved, in the full cutting process, when the spindle is sensed to be low in load, the machine tool is switched to be high-speed feeding, and when the spindle is sensed to be high in load, the machine tool is switched to be low-speed feeding.
The above description is only an embodiment of the present invention, but the structural features of the present invention are not limited thereto, and any changes or modifications within the scope of the present invention by those skilled in the art are covered by the present invention.
Claims (10)
1. A whole-course self-sensing self-adaptive cutting method for a machine tool comprises a main shaft motor output load rate calculator configured by a machine tool numerical control system, a PMC programmable controller and a human-computer interface set by related parameters, and is characterized in that: the method comprises the steps that the actual feeding speed of a machine tool = a program feeding speed value multiplied by feeding multiplying power is determined, the output load rate and the change amplitude of a spindle motor are sensed and detected in real time through a PMC program, the feeding cutting multiplying power value of the machine tool is adaptively changed and adjusted through software algorithm and control, the adaptive cutting of the feeding speed of the machine tool is controlled, and the output load rate data of the spindle motor in the machining process can be monitored in real time through a numerical control system; reading a spindle motor output load rate value and calculating a load rate change fluctuation data value through a programmable controller PMC software program in a real-time self-sensing manner, calculating a spindle motor load rate change fluctuation value through a machine tool machining heavy-entry cutter section PMC self-sensing detection, automatically reducing a feed cutting multiplying power to a cutter entry section self-adaptive initial feed multiplying power E when a cutter entry section spindle load change threshold value A is exceeded, and automatically gradually increasing the feed cutting multiplying power to restore the standard value to 100% in a set time D; PMC self-perception detects the load rate data value of the spindle motor in the full cutting process of machine tool machining, when exceeding the upper limit value H of the spindle load, the automatic adjustment is gradually decreased at intervals of 10% multiplying power value, and the multiplying power adjustment is stopped until the load rate of the spindle motor is lower than H; when the load rate of the spindle motor is lower than a spindle load reference value J, automatically adjusting the spindle motor to gradually increase at intervals of 10% of multiplying power values until the maximum value K of the self-adaptive feed cutting multiplying power is reached and then stopping multiplying power adjustment; the PMC self-perception detection main shaft motor load rate change fluctuation of the cutter outlet section is achieved, when the load rate is lower than a cutter outlet section main shaft load change threshold B, the feed cutting multiplying power is automatically reduced to the cutter outlet section self-adaptive initial feed multiplying power F, and the feed cutting multiplying power is automatically and gradually increased to be restored to a standard value of 100% step by step within set time D.
2. The machine tool full self-perception adaptive cutting method according to claim 1, characterized in that: through PMC program self-perception detection and algorithm, main shaft load rate data and calculation fluctuation data are obtained, and feed cutting multiplying power values of a cutter entering section, a full cutting process and a cutter discharging section are automatically controlled and adjusted:
entering a cutter section: in a set period of a data register C value of main shaft load change acquisition time, PMC acquires, stores and senses a register value of actually measured main shaft motor load rate data at intervals, differential subtraction operation is carried out on load rates before and after the set period of acquisition time, an operation result value is input blade section main shaft motor load rate fluctuation data, and an operation formula is as follows: the result value = main shaft load rate value after the acquisition time C-main shaft load rate value before the acquisition time C, when the operation result value is greater than the set threshold value A, the self-adaptive feed control is started, the PMC modifies the assigned data of the feed cutting multiplying factor register, so that the feed cutting multiplying factor is reduced to the set value E, the automatic adjustment control method of the feed cutting multiplying factor stepwise increment is completed within the set time D, the feed cutting multiplying factor is gradually restored to 100%, and the self-adaptive control of the tool entering section is finished;
full-cutter cutting section: the PMC detects and acquires a register value of the current spindle motor output load rate data in a self-sensing mode in real time, when the current spindle load rate exceeds a set upper limit threshold value H, self-adaptive feed control is started, the PMC modifies a rate value at intervals and decreases at a speed of 10%, and the PMC recalculates and compares whether the spindle load rate exceeds the threshold value H or not every time until the spindle load rate is lower than the threshold value H, and self-adaptive control is stopped;
full-cutter cutting section: the PMC detects and collects a current spindle motor output load rate data register value in a self-sensing mode in real time, when the current spindle load rate is lower than a set load reference value J, self-adaptive feed control is started, the PMC modifies a rate value at intervals and increases the rate at a speed of 10%, the spindle load rate is recalculated and compared every time, the feed rate is gradually increased along with the increase of the feed rate, the spindle load is gradually increased along with the increase of the feed rate, and the self-adaptive feed control is stopped until the spindle load rate is higher than the reference value J; increasing the maximum value K of the self-adaptive multiplying power, and in the process of gradually increasing the feed cutting multiplying power and gradually increasing the load rate of the main shaft, adaptively adjusting the maximum multiplying power value not to exceed the value K;
a cutter discharging section: in a set period of a data register C value of main shaft load change acquisition time, the PMC collects and stores register values of actually measured sensing main shaft motor load rate data at intervals, differential subtraction operation is carried out on load rates before and after the set period of acquisition time, and an operation result value is input section main shaft motor load rate fluctuation data; the operational formula is as follows: and the result value = main shaft load rate value after the acquisition time C-main shaft load rate value before the acquisition time C, when the operation result value is smaller than a set threshold value B, starting adaptive feed control, modifying the assigned data of the feed cutting multiplying factor register by the PMC to reduce the feed cutting multiplying factor to a set value F, finishing an automatic adjustment control method of stepwise increasing the feed cutting multiplying factor within a set time D, gradually recovering the feed cutting multiplying factor to 100%, and finishing the adaptive control of a tool discharging section.
3. The machine tool full self-perception adaptive cutting method according to claim 2, characterized in that: and a spindle load change threshold A of the cutter entering section corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the value A is within an allowable range of 0-50%/ms.
4. The machine tool full self-perception adaptive cutting method according to claim 2, characterized in that: and a spindle load change threshold B of the cutting section corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the value B is within an allowable range of 0 to-50%/ms.
5. The machine tool full self-perception adaptive cutting method according to claim 2, characterized in that: and C, acquiring time C of load change of the tool entering and exiting, wherein the C corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the allowable range of the parameter setting data of the C value is 4-10 ms.
6. The machine tool full self-perception adaptive cutting method according to claim 2, characterized in that: and D is the maintenance time D of the self-adaptive state of the tool entering and exiting, the D corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value allowable range of the D value is 2-6 s.
7. The machine tool full self-perception adaptive cutting method according to claim 2, characterized in that: the feed cutting multiplying power stepped control method indicates that the self-adaptive initial feed cutting multiplying power E value of a cutter entering section is subjected to stepped incremental assignment by modifying feed cutting multiplying power data register data through a PMC at fixed 2-second intervals, a corresponding input window is arranged on a system functional interface, and the parameter setting numerical value allowable range of the E value is 10-50%.
8. The machine tool full self-perception adaptive cutting method according to claim 2, characterized in that: the feed cutting multiplying power stepped control method indicates that the self-adaptive initial feed cutting multiplying power F value of a cutter section is modified through the PMC to carry out stepped incremental assignment according to fixed 2-second intervals, a corresponding input window is arranged on a system functional interface, and the parameter setting numerical value allowable range of the F value is 10-40%.
9. The machine tool full self-perception adaptive cutting method according to claim 2, characterized in that: the main shaft load upper limit value H corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the H value is within an allowable range of 0-150%; in the full cutting process, sensing and detecting that the spindle load rate is larger than an upper limit value H, if the state is kept for a fixed time, triggering adaptive control, modifying the feed cutting multiplying power by interval time by the PMC, and gradually reducing and assigning at a speed of 10% until the current spindle load rate is smaller than the upper limit value H, and stopping adaptive feed adjustment.
10. The machine tool full self-perception adaptive cutting method according to claim 2, characterized in that: the main shaft load upper limit value J corresponds to a PMC data register, a corresponding input window is arranged on a system interface, and the parameter setting numerical value of the J value is in an allowable range of 0-130%; in the full cutting process, sensing and detecting that the load rate of a spindle is smaller than a reference value J, if the state is kept for a fixed time, triggering adaptive control, modifying feed cutting multiplying power by interval time by a PMC (physical control center) and carrying out incremental assignment at a speed of 10 percent to ensure that the load rate of the spindle gradually approaches the reference value J, and stopping adaptive feed adjustment when the load rate of the spindle is larger than J; and (4) adjusting the self-adaptive feed cutting multiplying power to increase the maximum value K, and stopping the self-adaptive adjustment after the K value is reached.
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Denomination of invention: A method of machine tool self sensing adaptive cutting Effective date of registration: 20221106 Granted publication date: 20220401 Pledgee: Zhejiang Xiaoshan rural commercial bank Limited by Share Ltd. Lin Pu branch Pledgor: Hangzhou Junyu Technology Co.,Ltd. Registration number: Y2022330002989 |
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