CN114054785A - Fault detection method, system, computer readable storage medium and numerical control machine tool - Google Patents
Fault detection method, system, computer readable storage medium and numerical control machine tool Download PDFInfo
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Abstract
The invention provides a fault detection method, a fault detection system, a computer readable storage medium and a numerical control machine tool, which are applied to the numerical control machine tool and used for detecting a main shaft and a feed shaft of the numerical control machine tool; the fault detection method comprises the following steps: generating an operation program of the numerical control machine tool; after the numerical control machine enters an operating state, acquiring the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction; and analyzing the faults of the main shaft and the feeding shaft according to the operation data of the main shaft and the operation data of the feeding shafts in the three-dimensional direction. According to the invention, the main shaft and the feed shaft are subjected to accurate fault diagnosis by collecting and analyzing the speed fluctuation of the feed shaft when the main shaft rotates, so that equipment faults can be found in time, the detection cost does not need to be increased, and the field implementation is facilitated.
Description
Technical Field
The invention belongs to the field of detection and signal processing of numerical control machines, relates to a detection method and a detection system, and particularly relates to a fault detection method and system, a computer readable storage medium and a numerical control machine.
Background
At present, external detection equipment such as a vibration sensor and analysis equipment thereof is generally required to be used for detecting faults of mechanical transmission parts of a numerical control machine tool or other numerical control equipment, and the related equipment has high cost and difficult field implementation. Typically, for cost reasons, a user of a numerically controlled machine tool or other numerically controlled equipment will not be dedicated to purchasing the relevant detection equipment. The conventional mechanical detection method usually needs to disassemble the machine, and is difficult to implement on site. On-site fault judgment of the main shaft and the feed shaft depends on experience, problems can be found only when serious processing problems occur, and at the moment, key parts are damaged and difficult to maintain.
Therefore, how to provide a fault detection method, system, computer readable storage medium and numerically controlled machine tool to solve the technical problem that in the prior art, the fault judgment of the spindle and the feed shaft depends on experience, so that the problem is found only when the numerically controlled machine tool has a serious processing problem, the critical component is damaged, the maintenance is difficult, and the like.
Disclosure of Invention
In view of the above-mentioned shortcomings of the prior art, an object of the present invention is to provide a fault detection method, system, computer-readable storage medium and numerically controlled machine tool, which are used to solve the problems that in the prior art, the fault determination of the spindle and the feed shaft depends on experience, and therefore, the problem is found only when the numerically controlled machine tool has a serious processing problem, which results in damage to key components and difficulty in maintenance.
In order to achieve the above and other related objects, an aspect of the present invention provides a fault detection method for a numerically controlled machine tool, for detecting a spindle and a feed shaft of the numerically controlled machine tool; the fault detection method comprises the following steps: generating an operation program of the numerical control machine tool; after the numerical control machine enters an operating state, acquiring the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction; and analyzing the faults of the main shaft and the feeding shaft according to the operation data of the main shaft and the operation data of the feeding shafts in the three-dimensional direction.
In an embodiment of the present invention, the generated operation program of the numerical control machine tool includes an operation program instructing the main shaft to operate according to a predetermined motion and an operation program instructing each of the feed shafts in the three-dimensional direction to operate to a predetermined position.
In an embodiment of the present invention, the operation data of the spindle includes a stable rotation speed of the spindle; the operation data of each feeding shaft in the three-dimensional direction comprises feedback speed of each feeding shaft in the three-dimensional direction.
In an embodiment of the present invention, the step of analyzing the faults of the spindle and the feed shaft according to the operation data of the spindle and the operation data of each feed shaft in the three-dimensional direction includes: and dividing the test process into a plurality of test sections according to the stable rotating speed of the main shaft.
In an embodiment of the present invention, the step of analyzing the faults of the spindle and the feed shaft according to the operation data of the spindle and the operation data of each feed shaft in the three-dimensional direction includes: when the main shaft enters a testing section, acquiring the feedback speed of each feeding shaft at n data points in the three-dimensional direction at a stable rotating speed in the testing section; wherein n represents the number of data points of the main shaft at the stable rotating speed; respectively calculating the average fluctuation value of the speed of each feeding shaft in the three-dimensional direction; determining whether the stable rotating speed is a meaningful rotating speed of the feeding shaft or not according to the average speed fluctuation value of each feeding shaft; if so, selecting a plurality of continuous data points from the feedback speed within the staying time period under the stable rotating speed, and carrying out Fourier transform on the plurality of continuous data points; if not, entering the next test section; selecting the maximum amplitude values corresponding to the number of the amplitude values according to the specified number from the amplitude values of the Fourier transform, and forming a maximum frequency peak value matrix by the frequency corresponding to the selected maximum amplitude values; judging whether a common frequency exists in the maximum frequency peak value matrix; if yes, the feed shaft is indicated to have a resonance phenomenon; if not, the feed shaft is normal.
In an embodiment of the present invention, the step of analyzing the faults of the spindle and the feed shaft according to the operation data of the spindle and the operation data of each feed shaft in the three-dimensional direction further includes: calculating the proportion of the common frequency of each feed shaft in the feedback speed fluctuation; calculating a speed fluctuation index of each feed shaft according to the proportion; the speed fluctuation index is an index for judging whether the main shaft has a fault or not; and if the speed fluctuation index of the feeding shaft connected with the main shaft is greater than a preset main shaft fault threshold value, indicating that the main shaft has a radial run-out over-tolerance fault.
In an embodiment of the present invention, the step of analyzing the faults of the spindle and the feed shaft according to the operation data of the spindle and the operation data of each feed shaft in the three-dimensional direction further includes: calculating the second frequency multiplication and the half frequency of the main shaft power frequency according to the main shaft rotating power frequency under a stable rotating speed of the main shaft; judging whether a double frequency or a half frequency of the main shaft rotation power frequency exists in a maximum frequency peak value matrix of a feeding shaft connected with the main shaft; if the spindle is not centered, the spindle is not centered.
The invention provides a fault detection system, which is applied to a numerical control machine tool and is used for detecting a main shaft and a feed shaft of the numerical control machine tool; the fault detection system includes: the program generating module is used for generating an operation program of the numerical control machine tool; the data acquisition module is used for acquiring the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction after the numerical control machine enters an operation state; and the fault analysis module is used for carrying out fault analysis on the main shaft and the feeding shaft according to the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction.
Yet another aspect of the present invention provides a computer-readable storage medium having stored thereon a computer program which, when executed by a processor, implements the fault detection method.
In a final aspect, the present invention provides a numerically controlled machine tool, comprising: a processor and a memory; the memory is used for storing computer programs, and the processor is used for executing the computer programs stored by the memory so as to enable the numerical control machine tool to execute the fault detection method.
As described above, the fault detection method, system, computer readable storage medium and numerical control machine tool according to the present invention have the following advantages:
according to the fault detection method, the fault detection system, the computer-readable storage medium and the numerical control machine tool, the main shaft and the feeding shaft are subjected to accurate fault diagnosis by collecting and analyzing the speed fluctuation of the feeding shaft when the main shaft rotates, so that equipment faults can be found in time, the detection cost does not need to be increased, and the field implementation is facilitated.
Drawings
Fig. 1 is a flowchart illustrating a fault detection method according to an embodiment of the invention.
Fig. 2A is a schematic flow chart of S13 in the fault detection method of the present invention.
Fig. 2B is a schematic flow chart of S13 in the fault detection method of the present invention.
Fig. 2C is a schematic flow chart of S13 in the fault detection method of the present invention.
Fig. 3 is a schematic structural diagram of a fault detection system according to an embodiment of the invention.
Description of the element reference numerals
3 Fault detection System
31 program generating module
32 data acquisition module
33 failure analysis module
S11-S13
S131 to S138 steps
S131' to S133
S131 'to S132' steps
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention. It is to be noted that the features in the following embodiments and examples may be combined with each other without conflict.
It should be noted that the drawings provided in the following embodiments are only for illustrating the basic idea of the present invention, and the components related to the present invention are only shown in the drawings rather than drawn according to the number, shape and size of the components in actual implementation, and the type, quantity and proportion of the components in actual implementation may be changed freely, and the layout of the components may be more complicated.
Example one
The embodiment provides a fault detection method, which is applied to a numerical control machine tool and used for detecting a main shaft and a feed shaft of the numerical control machine tool; the fault detection method comprises the following steps:
generating an operation program of the numerical control machine tool;
after the numerical control machine enters an operating state, acquiring the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction;
and analyzing the faults of the main shaft and the feeding shaft according to the operation data of the main shaft and the operation data of the feeding shafts in the three-dimensional direction.
The failure detection method provided by the present embodiment will be described in detail below with reference to the drawings. Please refer to fig. 1, which is a flowchart illustrating a fault detection method according to an embodiment. As shown in fig. 1, the fault detection method specifically includes the following steps:
and S11, generating an operation program of the numerical control machine tool.
In this embodiment, the generated operation program of the numerical control machine tool includes an operation program instructing the main spindle to operate in accordance with a specified motion and an operation program instructing each of the feed axes in the three-dimensional direction (XYZ direction) to operate to a specified position.
Specifically, the operation program of the spindle operating according to the designated motion includes that the maximum spindle rotation speed is indicated to be 20000 rpm, the set rotation speed interval is 2000, the spindle stays for 2 seconds at rotation speeds of [0, 2000, 4000, 6000, 8000, 10000, 12000, 14000, 16000, 18000 and 20000] respectively in the test process, and finally, the program is decelerated to 0, and the operation is completed.
The given position of the feed shaft may typically be set as the centre of the range of motion of the shaft, and the given movement of the main shaft is accelerated from 0 to a given rotational speed at set rotational speed intervals during which it stays for a period of time, e.g. 2 seconds, at each rotational speed interval.
And S12, acquiring the operation data of the main shaft and the operation data of each feed shaft in the three-dimensional direction after the numerical control machine tool enters the operation state.
In this embodiment, the operation data of the spindle includes data such as a stable rotation speed of the spindle. The operation data of each feeding shaft in the three-dimensional direction comprises data such as feedback speed of each feeding shaft in the three-dimensional direction (XYZ three-axis).
And S13, analyzing the faults of the main shaft and the feed shaft according to the operation data of the main shaft and the operation data of the feed shaft in the three-dimensional direction.
Please refer to fig. 2A, which shows a schematic flow chart of S13. As shown in fig. 2A, the S13 specifically includes the following steps:
s131, dividing the testing process into a plurality of testing sections according to the stable rotating speed of the main shaft.
S132, when the main shaft enters a testing section, acquiring the feedback speed of each feeding shaft at n data points in the three-dimensional direction at a stable rotating speed in the testing section; wherein n represents the number of data points of the main shaft at the stable rotating speed.
For example, the stable rotation speed of the main shaft is 12000 r/min, and the feedback speed of the X axis of a certain milling machine is vel _ X12000＝[vel_x(1),vel_x(2)...vel_x(n)]The YZ axis is the same.
And S133, respectively calculating the average speed fluctuation value vel _ vib of each feeding shaft in the three-dimensional direction.
For example, taking the case where the X-axis is at 12000 rpm, the calculation formula of the average fluctuation value vel _ vib of the speed is as follows:
vel_vibx12000＝mean(abs(vel_x12000))
wherein abs is the absolute value of the calculation, and mean is the mean value of the calculation.
S134, determining whether the stable rotating speed is a meaningful rotating speed of the feeding shaft or not according to the average speed fluctuation value of each feeding shaft; if yes, go to step S135, otherwise go to the next test segment.
In this embodiment, when the average speed fluctuation value vel _ vib is greater than the preset fluctuation threshold value vel _ th (determined by the accuracy of the feedback element selected for the feed shaft, which is usually a speed fluctuation value corresponding to 2 to 3 pulses), it is determined that the speed fluctuation data at the stable rotation speed is significant, and the stable rotation speed of the main shaft is determined as a significant rotation speed.
And S135, selecting a plurality of continuous data points from the feedback speed within the staying time period at the stable rotating speed, and carrying out Fourier transform on the plurality of continuous data points.
For example, taking data at a rotational speed of 12000 rpm as an example, at a sampling frequency of 1000hz, the data length of 2 seconds of stay at each rotational speed is about 2000, and 1024 data points are continuously taken from the data and fourier-transformed for consistency analysis.
S136, selecting the maximum amplitude values corresponding to the number of the amplitude values according to the specified number from the Fourier transform amplitude values, and forming the frequency corresponding to the selected maximum amplitude values into a maximum frequency peak value matrix.
Specifically, in the amplitude result of fourier transform, frequencies corresponding to 5 maximum amplitudes are selected to form a maximum frequency peak value matrix peak _ set, where peak _ set is [ f ═ f12000_max1,f12000_max2,f12000_max3,f12000_max4,f12000_max5]
S137, determining whether the maximum frequency peak value matrix has the common frequency f _ r (also called as a resonant frequency); if yes, the feed shaft is indicated to have a resonance phenomenon; if not, the feed shaft is normal.
Specifically, when the common frequency f _ r is determined, if n groups of significant rotation speeds exist in the test result, f _ r is considered to be a valid resonance frequency when n × 0.6 times or more of the significant rotation speeds exist in f _ r, that is, the feed shaft is considered to be in resonance.
In the maximum frequency peak matrix peak _ set, when the deviation of two frequencies is within ± 2hz, the values are considered to be the same due to the influence of frequency resolution, and are considered as the repetition frequencies.
Please refer to fig. 2B, which shows a schematic flow chart of S13. As shown in fig. 2B, the S13 further includes the following steps:
s131', after the resonant frequency f _ r is determined, the ratio of the common frequency to the feedback velocity fluctuation is calculated for each of the feed axes.
At a significant speed, the magnitude result of the Fourier transform is expressed as [ m [ ]f1,mf2,mf3,...,mfn]Where m represents the amplitude and fn represents its corresponding frequency. The calculation formula of the proportion r _ p of the common frequency in the feedback velocity fluctuation is as follows:
wherein m iskThe amplitude corresponding to the resonance frequency f _ r is sum.
S132', calculating a speed fluctuation index vel _ m of each feeding shaft according to the proportion; the speed fluctuation index is an index for determining whether the main shaft has a fault.
Speed fluctuation index vel _ m at a significant speedjThe calculation formula of (a) is as follows:
vel_mj＝r_pj×vel_vibj
for each feed shaft, the vel _ m at each meaningful rotation speedjAnd (4) taking an average value to obtain a speed fluctuation index vel _ m of each feeding shaft.Since the vel _ m of the feed shaft directly connected to the main shaft in the actual situation most reflects the main shaft situation, the value of vel _ m calculated using the feed shaft data connected to the main shaft is mainly considered in determining the main shaft failure. If the axis connecting a certain machine tool and the main shaft is the z axis, mainly considering vel _ mzThe numerical value of (c).
S133', judging whether a speed fluctuation index vel _ m of a feeding shaft connected with the main shaft is larger than a preset main shaft fault threshold value vel _ m _ th (the main shaft fault threshold value vel _ m _ th is determined according to machine tools of different models, if the average vel _ m value of a plurality of machine tools of the same model is selected as vel _ m _ th); if the speed fluctuation index vel _ m of the feeding shaft connected with the main shaft is larger than a preset main shaft fault threshold value vel _ m _ th, the main shaft is indicated to have a mechanical fault, and if the main shaft has a radial run-out over-tolerance fault.
Referring to fig. 2C, which is a schematic flow chart of S13, as shown in fig. 2C, the S13 further includes:
and S131' calculating the double frequency (2X main shaft power frequency hz) and the half frequency (0.5X main shaft power frequency hz) of the main shaft power frequency according to the main shaft rotation power frequency (main shaft rotation speed/60) hz for each meaningful rotation speed.
S132', judging whether a double frequency or a half frequency of the main shaft rotation power frequency exists in a maximum frequency peak value matrix of a feeding shaft connected with the main shaft; if yes, indicating that the main shaft has a mechanical fault, namely that the main shaft has an misalignment fault; and if not, indicating that the main shaft has no mechanical fault.
Specifically, assuming that n groups of significant rotation speeds exist in the test result, the mechanical fault of the spindle is considered to exist only when the frequency which is twice or half the main shaft rotation power frequency is n x 0.6 times or more in the significant rotation speeds.
In this embodiment, the analysis process of the resonance fault of the feed shaft, the analysis process of the radial run-out fault of the spindle and the analysis process of the misalignment fault of the spindle may be performed simultaneously or sequentially.
According to the fault detection method, the main shaft and the feed shaft are subjected to accurate fault diagnosis by collecting and analyzing the speed fluctuation of the feed shaft when the main shaft rotates, so that equipment faults can be found in time, the detection cost does not need to be increased, and the field implementation is facilitated.
The present embodiment also provides a computer-readable storage medium having stored thereon a computer program which, when executed by a processor, implements the fault detection method.
One of ordinary skill in the art will appreciate that the computer-readable storage medium is: all or part of the steps for implementing the above method embodiments may be performed by hardware associated with a computer program. The aforementioned computer program may be stored in a computer readable storage medium. When executed, the program performs steps comprising the method embodiments described above; and the aforementioned storage medium includes: various media that can store program codes, such as ROM, RAM, magnetic or optical disks.
Example two
The embodiment provides a fault detection system, which is applied to a numerical control machine tool and used for detecting a main shaft and a feed shaft of the numerical control machine tool; the fault detection system includes:
the program generating module is used for generating an operation program of the numerical control machine tool;
the data acquisition module is used for acquiring the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction after the numerical control machine enters an operation state;
and the fault analysis module is used for carrying out fault analysis on the main shaft and the feeding shaft according to the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction.
The fault detection system provided by the present embodiment will be described in detail below with reference to the drawings. Please refer to fig. 3, which is a schematic structural diagram of a fault detection system in an embodiment. As shown in fig. 3, the failure detection system 3 includes: a program generating module 31, a data collecting module 32 and a fault analyzing module 33.
The program generating module 31 is used for generating an operation program of the numerical control machine tool.
In this embodiment, the operation program of the numerical control machine tool generated by the program generation module 31 includes an operation program instructing the main spindle to operate in accordance with a specified motion and an operation program instructing each of the feed axes in the three-dimensional direction (XYZ direction) to operate to a specified position.
The data acquisition module 32 is configured to acquire the operation data of the main shaft and the operation data of each feed shaft in the three-dimensional direction after the numerical control machine enters an operation state. In this embodiment, the operation data of the spindle includes data such as a stable rotation speed of the spindle. The operation data of each feeding shaft in the three-dimensional direction comprises data such as feedback speed of each feeding shaft in the three-dimensional direction (XYZ three-axis).
The failure analysis module 33 coupled to the program generation module 31 and the data acquisition module 32 is configured to perform failure analysis on the spindle and the feed shaft according to the operation data of the spindle and the operation data of each feed shaft in the three-dimensional direction.
Specifically, the fault analysis module 33 divides the testing process into a plurality of testing sections according to the stable rotation speed of the spindle; when the main shaft enters a testing section, acquiring the feedback speed of each feeding shaft at n data points in the three-dimensional direction at a stable rotating speed in the testing section; wherein n represents the number of data points of the main shaft at the stable rotating speed; respectively calculating the average fluctuation value vel _ vib of the speed of each feeding shaft in the three-dimensional direction; determining whether the stable rotating speed is a meaningful rotating speed of the feeding shaft or not according to the average speed fluctuation value of each feeding shaft; if so, selecting a plurality of continuous data points from the feedback speed within the staying time period under the stable rotating speed, and carrying out Fourier transform on the plurality of continuous data points; if not, entering the next test section; selecting the maximum amplitude values corresponding to the number of the amplitude values according to the specified number from the amplitude values of the Fourier transform, and forming a maximum frequency peak value matrix by the frequency corresponding to the selected maximum amplitude values; judging whether a common frequency f _ r (also called a resonance frequency) exists in the maximum frequency peak value matrix; if yes, the feed shaft is indicated to have a resonance phenomenon; if not, the feed shaft is normal.
Specifically, the failure analysis module 33 calculates the common frequency of each of the feed shafts after determining the resonant frequency f _ rThe ratio of frequency in the feedback velocity ripple; according to the proportion, calculating the speed fluctuation index vel _ m of each feeding shaftj(ii) a The speed fluctuation index is an index for judging whether the main shaft has a fault or not; judging whether a speed fluctuation index vel _ m of a feeding shaft connected with the main shaft is larger than a preset main shaft fault threshold value vel _ m _ th; if the speed fluctuation index vel _ m of the feeding shaft connected with the main shaft is larger than a preset main shaft fault threshold value vel _ m _ th, the main shaft is indicated to have a mechanical fault, and if the main shaft has a radial run-out over-tolerance fault.
Specifically, the fault analysis module 33 calculates, for each significant rotation speed, a double frequency (2 × main shaft power frequency hz) and a half frequency (0.5 × main shaft power frequency hz) of the main shaft power frequency according to the main shaft rotation power frequency (main shaft rotation speed/60) hz; judging whether a double frequency or a half frequency of the main shaft rotation power frequency exists in a maximum value peak value matrix of a feeding shaft connected with the main shaft; if yes, indicating that the main shaft has a mechanical fault, namely that the main shaft has an misalignment fault; and if not, indicating that the main shaft has no mechanical fault.
It should be noted that the division of the modules of the above system is only a logical division, and the actual implementation may be wholly or partially integrated into one physical entity, or may be physically separated. And the modules can be realized in a form that all software is called by the processing element, or in a form that all the modules are realized in a form that all the modules are called by the processing element, or in a form that part of the modules are called by the hardware. For example: the x module can be a separately established processing element, and can also be integrated in a certain chip of the system. In addition, the x-module may be stored in the memory of the system in the form of program codes, and may be called by one of the processing elements of the system to execute the functions of the x-module. Other modules are implemented similarly. All or part of the modules can be integrated together or can be independently realized. The processing element described herein may be an integrated circuit having signal processing capabilities. In implementation, each step of the above method or each module above may be implemented by an integrated logic circuit of hardware in a processor element or an instruction in the form of software. These above modules may be one or more integrated circuits configured to implement the above methods, such as: one or more Application Specific Integrated Circuits (ASICs), one or more microprocessors (DSPs), one or more Field Programmable Gate Arrays (FPGAs), and the like. When a module is implemented in the form of a Processing element scheduler code, the Processing element may be a general-purpose processor, such as a Central Processing Unit (CPU) or other processor capable of calling program code. These modules may be integrated together and implemented in the form of a System-on-a-chip (SOC).
EXAMPLE III
This embodiment provides a digit control machine tool, digit control machine tool includes: a processor, memory, transceiver, communication interface, or/and system bus; the memory and the communication interface are connected with the processor and the transceiver through a system bus and are used for completing mutual communication, the memory is used for storing the computer program, the communication interface is used for communicating with other equipment, and the processor and the transceiver are used for operating the computer program so that the numerical control machine tool can execute the steps of the fault detection method.
The above-mentioned system bus may be a Peripheral Component Interconnect (PCI) bus, an Extended Industry Standard Architecture (EISA) bus, or the like. The system bus may be divided into an address bus, a data bus, a control bus, and the like. For ease of illustration, only one thick line is shown, but this does not mean that there is only one bus or one type of bus. The communication interface is used for realizing communication between the database access device and other equipment (such as a client, a read-write library and a read-only library). The Memory may include a Random Access Memory (RAM), and may further include a non-volatile Memory (non-volatile Memory), such as at least one disk Memory.
The Processor may be a general-purpose Processor, and includes a Central Processing Unit (CPU), a Network Processor (NP), and the like; the Integrated Circuit may also be a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA) or other Programmable logic device, discrete Gate or transistor logic device, or discrete hardware components.
The protection scope of the fault detection method of the present invention is not limited to the execution sequence of the steps listed in this embodiment, and all the solutions implemented by adding, subtracting, and replacing steps in the prior art according to the principles of the present invention are included in the protection scope of the present invention.
The invention also provides a fault detection system, which can implement the fault detection method of the invention, but the implementation device of the fault detection method of the invention includes but is not limited to the structure of the fault detection system listed in the embodiment, and all the structural modifications and substitutions of the prior art made according to the principle of the invention are included in the protection scope of the invention.
In summary, the fault detection method, the fault detection system, the computer-readable storage medium and the numerical control machine tool provided by the invention can be used for accurately diagnosing the faults of the main shaft and the feed shaft by collecting and analyzing the speed fluctuation of the feed shaft when the main shaft rotates, so that the equipment fault can be found in time, the detection cost does not need to be increased, and the field implementation is facilitated. The invention effectively overcomes various defects in the prior art and has high industrial utilization value.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
Claims (10)
1. A fault detection method is characterized in that the fault detection method is applied to a numerical control machine tool and is used for detecting a main shaft and a feed shaft of the numerical control machine tool; the fault detection method comprises the following steps:
generating an operation program of the numerical control machine tool;
after the numerical control machine enters an operating state, acquiring the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction;
and analyzing the faults of the main shaft and the feeding shaft according to the operation data of the main shaft and the operation data of the feeding shafts in the three-dimensional direction.
2. The failure detection method according to claim 1, wherein the generated operation program of the numerically controlled machine tool includes an operation program instructing the main spindle to operate in accordance with a prescribed motion and an operation program instructing each of the feed axes in the three-dimensional direction to operate to a prescribed position.
3. The fault detection method of claim 1,
the operation data of the main shaft comprises the stable rotating speed of the main shaft;
the operation data of each feeding shaft in the three-dimensional direction comprises feedback speed of each feeding shaft in the three-dimensional direction.
4. The failure detection method according to claim 3, wherein the step of performing failure analysis of the main shaft and the feed shaft based on the operation data of the main shaft and the operation data of each of the feed shafts in the three-dimensional direction includes:
and dividing the test process into a plurality of test sections according to the stable rotating speed of the main shaft.
5. The failure detection method according to claim 4, wherein the step of performing failure analysis of the main shaft and the feed shaft based on the operation data of the main shaft and the operation data of each of the feed shafts in the three-dimensional direction includes:
when the main shaft enters a testing section, acquiring the feedback speed of each feeding shaft at n data points in the three-dimensional direction at a stable rotating speed in the testing section; wherein n represents the number of data points of the main shaft at the stable rotating speed;
respectively calculating the average fluctuation value of the speed of each feeding shaft in the three-dimensional direction;
determining whether the stable rotating speed is a meaningful rotating speed of the feeding shaft or not according to the average speed fluctuation value of each feeding shaft; if so, selecting a plurality of continuous data points from the feedback speed within the staying time period under the stable rotating speed, and carrying out Fourier transform on the plurality of continuous data points; if not, entering the next test section;
selecting the maximum amplitude values corresponding to the number of the amplitude values according to the specified number from the amplitude values of the Fourier transform, and forming a maximum frequency peak value matrix by the frequency corresponding to the selected maximum amplitude values;
judging whether a common frequency exists in the maximum frequency peak value matrix; if yes, the feed shaft is indicated to have a resonance phenomenon; if not, the feed shaft is normal.
6. The failure detection method according to claim 5, wherein the step of performing failure analysis of the main shaft and the feed shaft based on the operation data of the main shaft and the operation data of each of the feed shafts in the three-dimensional direction further comprises:
calculating the proportion of the common frequency of each feed shaft in the feedback speed fluctuation;
calculating a speed fluctuation index of each feed shaft according to the proportion; the speed fluctuation index is an index for judging whether the main shaft has a fault or not;
and if the speed fluctuation index of the feeding shaft connected with the main shaft is greater than a preset main shaft fault threshold value, indicating that the main shaft has a radial run-out over-tolerance fault.
7. The failure detection method according to claim 4, wherein the step of performing failure analysis of the main shaft and the feed shaft based on the operation data of the main shaft and the operation data of each of the feed shafts in the three-dimensional direction further comprises:
calculating the second frequency multiplication and the half frequency of the main shaft power frequency according to the main shaft rotating power frequency under a stable rotating speed of the main shaft;
judging whether a double frequency or a half frequency of the main shaft rotation power frequency exists in a maximum frequency peak value matrix of a feeding shaft connected with the main shaft; if the spindle is not centered, the spindle is not centered.
8. A fault detection system is characterized by being applied to a numerical control machine tool and used for detecting a main shaft and a feed shaft of the numerical control machine tool; the fault detection system includes:
the program generating module is used for generating an operation program of the numerical control machine tool;
the data acquisition module is used for acquiring the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction after the numerical control machine enters an operation state;
and the fault analysis module is used for carrying out fault analysis on the main shaft and the feeding shaft according to the operation data of the main shaft and the operation data of each feeding shaft in the three-dimensional direction.
9. A computer-readable storage medium, on which a computer program is stored, which, when being executed by a processor, carries out the fault detection method according to any one of claims 1 to 7.
10. A numerically controlled machine tool, comprising: a processor and a memory;
the memory is used for storing a computer program, and the processor is used for executing the computer program stored by the memory so as to enable the numerical control machine tool to execute the fault detection method according to any one of claims 1 to 7.
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