WO2023151166A1

WO2023151166A1 - Dynamic protection method for mechanical part of machine tool, and computer numerical control machine tool device

Info

Publication number: WO2023151166A1
Application number: PCT/CN2022/085104
Authority: WO
Inventors: 魏振南; 程磊; 吴豪
Original assignee: 无锡微茗智能科技有限公司
Priority date: 2022-02-09
Filing date: 2022-04-02
Publication date: 2023-08-17
Also published as: TW202333010A; TWI832193B; CN114488950B; CN114488950A

Abstract

Provided herein are a dynamic protection method for a mechanical part of a machine tool, and a computer numerical control machine tool device. The dynamic protection method for a mechanical part of a machine tool comprises: acquiring a configuration parameter of a machine tool in the current operation scenario; acquiring data that is fed back by a three-axis acceleration sensor of the machine tool, and using same as first vibration data; sequentially performing data smoothing processing and data filtering processing on the first vibration data, so as to obtain second vibration data; according to the configuration parameter, performing calculation on the second vibration data, so as to obtain feature data; comparing the feature data with a preset threshold value, so as to obtain a comparison result; and according to the comparison result, determining an alarm mode, and adjusting the machine tool.

Description

机床机械部件动态保护方法及数控机床设备Dynamic protection method of machine tool mechanical parts and numerical control machine tool equipment

本公开要求于2022年02月09日提交中国专利局、申请号为202210122471.4、发明名称为“机床机械部件动态保护方法及数控机床设备”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。This disclosure claims the priority of the Chinese patent application with the application number 202210122471.4 and the title of the invention "Dynamic Protection Method for Machine Tool Mechanical Components and CNC Machine Tool Equipment" submitted to the China Patent Office on February 09, 2022, the entire contents of which are incorporated by reference In this application.

技术领域technical field

本公开涉及数控机床领域，例如涉及一种机床机械部件动态保护方法及数控机床设备。The present disclosure relates to the field of numerical control machine tools, for example, to a method for dynamic protection of machine tool mechanical parts and numerical control machine tool equipment.

背景技术Background technique

数控机床是数字控制机床(Computer numerical control machine tools)的简称，是一种装有程序控制***的自动化机床，程序控制***能够逻辑地处理具有控制编码或其他符号指令规定的程序，并将其译码，用代码化的数字表示，通过信息载体输入数控装置，经运算处理由数控装置发出各种控制信号控制机床的动作，数控机床按图纸要求的形状和尺寸，自动地将零件加工出来。数控机床较好地解决了复杂、精密、小批量、多品种的零件加工问题，是一种柔性的、高效能的自动化机床，代表了现代机床控制技术的发展方向，是一种典型的机电一体化产品。CNC machine tool is the abbreviation of Computer numerical control machine tools. It is an automatic machine tool equipped with a program control system. The program control system can logically process programs with control codes or other symbolic instructions and translate them. Code, represented by coded numbers, is input into the numerical control device through the information carrier, and the numerical control device sends out various control signals to control the movement of the machine tool after calculation processing. The numerical control machine tool automatically processes the parts according to the shape and size required by the drawing. CNC machine tools solve complex, precise, small-batch, and multi-variety parts processing problems. It is a flexible, high-efficiency automatic machine tool that represents the development direction of modern machine tool control technology. It is a typical mechatronics chemical products.

在实际生产中，数控机床加工运行，往往伴随着机床磨损、疲劳剥落、断裂、变形、腐蚀、断裂和老化等等问题，随着时间的推移，各种问题堆积，都会影响机床的正常运行，造成加工过程中故障。此外，操作人员的操作规范性，加工指令的正确性及合理性，都会影响机床的运行。实际上，在机床实际加工中，机床发生故障是常态，但一些重大故障，例如机床撞车、刀具脱落，不但会影响生产效率，损坏机床，甚至会威胁操作人员的人生安全。In actual production, the machining operation of CNC machine tools is often accompanied by problems such as machine tool wear, fatigue peeling, fracture, deformation, corrosion, fracture and aging. As time goes by, various problems accumulate, which will affect the normal operation of the machine tool. cause failure during processing. In addition, the standardization of the operator's operation, the correctness and rationality of the processing instructions will affect the operation of the machine tool. In fact, in the actual processing of machine tools, it is normal for machine tools to break down, but some major failures, such as machine tool crashes and tool shedding, will not only affect production efficiency, damage machine tools, but even threaten the safety of operators.

然而，依赖于操作人员的加工经验进行机床运行状态的判断，存在较大的局限性及不确定性，也有较大的安全隐患。辅助或代替人工进行机械异常识别检测的检测设备不能实时监控机械异常，无法及时给出反馈及警示，且反映故障问题过于滞后。However, relying on the processing experience of the operator to judge the operating state of the machine tool has great limitations and uncertainties, and also has great potential safety hazards. The detection equipment that assists or replaces manual mechanical abnormality identification and detection cannot monitor mechanical abnormalities in real time, cannot give timely feedback and warnings, and reflects fault problems too late.

发明内容Contents of the invention

本公开提供一种机床机械部件动态保护方法及数控机床设备；机床机械部件动态保护方法能够快速反馈机床故障信息，进行报警提示，并对机床做出调整，实现对机床的机械部件的动态保护，避免机床撞机；数控机床设备能够实时监测机床运行情况，在机床发生故障时，发出警示信息，并做出相应的调整，避免机床撞机。The present disclosure provides a dynamic protection method for machine tool mechanical parts and CNC machine tool equipment; the dynamic protection method for machine tool mechanical parts can quickly feed back machine tool fault information, give an alarm prompt, and make adjustments to the machine tool to realize dynamic protection for the machine tool mechanical parts. Avoid machine tool collision; CNC machine tool equipment can monitor the operation of the machine tool in real time, send a warning message when the machine tool fails, and make corresponding adjustments to avoid machine tool collision.

本公开提供一种机床机械部件动态保护方法，包括：The present disclosure provides a dynamic protection method for machine tool mechanical parts, including:

获取机床在当前运行场景下的配置参数，其中，配置参数包括预设阈值、高通值、低通值、延时参数和换算个数中的一个或多个；Obtain the configuration parameters of the machine tool in the current operating scenario, where the configuration parameters include one or more of preset thresholds, high-pass values, low-pass values, delay parameters and conversion numbers;

获取机床的三轴加速度传感器反馈的数据，将三轴加速度传感器反馈的数据作为第一振动数据，并对第一振动数据依次进行数据平滑处理和数据滤波处理，得到第二振动数据；Obtaining the data fed back by the three-axis acceleration sensor of the machine tool, using the data fed back by the three-axis acceleration sensor as the first vibration data, and sequentially performing data smoothing and data filtering processing on the first vibration data to obtain second vibration data;

根据配置参数对第二振动数据进行计算，获得特征数据，将特征数据与预设阈值进行对比，得到对比结果；其中，特征数据包括对第二振动数进行计算得到的峰峰值、平均值、均方根值、域值中的一种或多种；Calculate the second vibration data according to the configuration parameters to obtain characteristic data, compare the characteristic data with the preset threshold value, and obtain the comparison result; wherein, the characteristic data include the peak-to-peak value, average value, and average value obtained by calculating the second vibration number. One or more of square root value and domain value;

根据对比结果，确定报警方式，和/或对机床进行调整。According to the comparison result, determine the alarm mode, and/or adjust the machine tool.

在一实施例中，机床的运行场景包括：In one embodiment, the operating scenarios of the machine tool include:

快速进给场景、切削场景、换刀场景、重复加工监控场景、重点刀具监控场景、伺服轴磨损监控场景、重切削场景或自适应控制场景。Rapid feed scene, cutting scene, tool change scene, repetitive processing monitoring scene, key tool monitoring scene, servo shaft wear monitoring scene, heavy cutting scene or adaptive control scene.

在一实施例中，数据平滑处理的步骤包括：In one embodiment, the steps of data smoothing processing include:

获取机床的三轴加速度传感器反馈的X轴向、Y轴向、Z轴向的三轴向数据，其中，一个三轴向数据为一组数据，采集连续或不连续的3组数据，将该3组数据与采集这3组数据之前所采集的61组数据拼接为64组数据，64组数据作为第一振动数据；Obtain the three-axis data of the X-axis, Y-axis, and Z-axis fed back by the three-axis acceleration sensor of the machine tool. Among them, one three-axis data is a set of data, and three sets of continuous or discontinuous data are collected. The 3 sets of data and the 61 sets of data collected before these 3 sets of data are spliced into 64 sets of data, and the 64 sets of data are used as the first vibration data;

对第一振动数据中的X轴向数据、Y轴向数据、Z轴向数据分别求平均数，得到X轴向振动数据的平均数、Y轴向振动数据的平均数、Z轴向振动数据的平均数；将第一振动数据按照X轴向、Y轴向、Z轴向组成矩阵，并对X轴向振动数据的平均数、Y轴向振动数据的平均数、Z轴向振动数据的平均数做矩阵相减，得到三轴向的差值矩阵；Calculate the average of the X-axis data, Y-axis data, and Z-axis data in the first vibration data to obtain the average of the X-axis vibration data, the average of the Y-axis vibration data, and the Z-axis vibration data The average number; the first vibration data is formed into a matrix according to the X-axis, Y-axis, and Z-axis, and the average number of the X-axis vibration data, the average number of the Y-axis vibration data, and the Z-axis vibration data The average is subtracted from the matrix to obtain the difference matrix of the three axes;

将第一振动数据转化为余弦函数，得到64组数据中每组数据的余弦函数值：Convert the first vibration data into a cosine function, and obtain the cosine function value of each set of data in the 64 sets of data:

根据三轴向的差值矩阵及余弦函数进行窗函数处理，将对应的同一组三轴向数据的差值矩阵与其对应的余弦函数值相乘得到乘积，乘积即为窗函数数值。The window function is processed according to the three-axis difference matrix and the cosine function, and the corresponding difference matrix of the same group of three-axis data is multiplied by the corresponding cosine function value to obtain a product, and the product is the value of the window function.

在一实施例中，数据滤波处理的步骤包括：In one embodiment, the steps of data filtering processing include:

将窗函数数值进行傅里叶变换，得到窗函数数值频域数据；Perform Fourier transform on the window function value to obtain the frequency domain data of the window function value;

根据配置参数，对窗函数数值频域数据进行高低通滤波得到带通数据；According to the configuration parameters, perform high and low-pass filtering on the numerical frequency domain data of the window function to obtain band-pass data;

将带通数据进行傅里叶逆变换，得到第二振动数据。Inverse Fourier transform is performed on the bandpass data to obtain the second vibration data.

在一实施例中，根据配置参数对第二振动数据进行计算获得特征数据的步骤中：In one embodiment, in the step of calculating the second vibration data according to the configuration parameters to obtain the characteristic data:

当配置参数对应的场景为异常撞机场景时，特征参数包括平均值、峰峰值；When the scene corresponding to the configuration parameters is an abnormal collision scene, the characteristic parameters include average value and peak-to-peak value;

当配置参数对应的场景为切削过载场景时，特征参数包括平均值、均方根、峰峰值；When the scene corresponding to the configuration parameters is a cutting overload scene, the characteristic parameters include average value, root mean square, and peak-to-peak value;

当配置参数对应的场景为异常换刀场景时，特征参数包括平均值；When the scene corresponding to the configuration parameters is an abnormal tool change scene, the characteristic parameters include the average value;

当配置参数对应的场景为重切削场景时，特征参数包括平均值、均方根、峰峰值；When the scene corresponding to the configuration parameters is a heavy cutting scene, the characteristic parameters include average value, root mean square, and peak-to-peak value;

当配置参数对应的场景为各伺服轴磨损时，特征参数包括域值；When the scenario corresponding to the configuration parameters is that each servo axis is worn out, the characteristic parameters include threshold values;

当配置参数对应的场景为重复加工监控场景时，特征参数包括平均值和均方根；When the scene corresponding to the configuration parameters is a repeated processing monitoring scene, the characteristic parameters include average value and root mean square;

当配置参数对应的场景为重点刀具监控场景时，特征参数同时包括平均值、均方根和峰峰值；When the scene corresponding to the configuration parameters is a key tool monitoring scene, the characteristic parameters include the average value, root mean square and peak-to-peak value at the same time;

当配置参数对应的场景为自适应控制场景时，特征参数包括平均值和均方根；When the scenario corresponding to the configuration parameters is an adaptive control scenario, the characteristic parameters include average value and root mean square;

当配置参数对应的场景为自定义场景时，特征参数根据自定义场景进行设定。When the scene corresponding to the configuration parameters is a custom scene, the feature parameters are set according to the custom scene.

在一实施例中，特征参数的提取方式包括：In one embodiment, the extraction method of feature parameters includes:

峰峰值的获取方式为根据第二振动数据的波形图，计算波形图中的波峰波谷值；The peak-to-peak value is obtained by calculating the peak and valley values in the waveform diagram according to the waveform diagram of the second vibration data;

平均值的计算方法为获取第二振动数据，将同一组X轴向数据、Y轴向数据、Z轴向数据按照向量和的计算方法进行计算，得到该组数据的向量和，并与相邻时间采集的两组三轴向数据的向量和进行平均数计算，得到平均值；The calculation method of the average value is to obtain the second vibration data, calculate the same group of X-axis data, Y-axis data, and Z-axis data according to the calculation method of vector sum, obtain the vector sum of this group of data, and compare it with the adjacent The vector sum of the two sets of three-axis data collected at time is calculated to obtain the average value;

均方根的计算方法为获取第二振动数据，对第二振动数据中，以时间为基准，向后连续选取设定数量的以连续3组为基本单元的三轴向数据，每连续3组按照X轴向数据、Y轴向数据、Z轴向数据分别进行均方根的计算，再获取设定数量的基本单元的均方根进行均值计算；The root mean square calculation method is to obtain the second vibration data. For the second vibration data, based on time, continuously select a set number of triaxial data with 3 consecutive groups as the basic unit, and every 3 consecutive groups Calculate the root mean square according to the X-axis data, Y-axis data, and Z-axis data, and then obtain the root mean square of the set number of basic units for mean calculation;

域值的计算方法为获取第二振动数据的波动范围值。The calculation method of the threshold value is to obtain the fluctuation range value of the second vibration data.

在一实施例中，根据对比结果，确定报警方式，和/或对机床进行调整的步骤包括：In one embodiment, according to the comparison result, the steps of determining the alarm mode and/or adjusting the machine tool include:

当对比结果小于预设阈值，则机床维持所述机床操作状态；When the comparison result is less than the preset threshold, the machine tool maintains the machine tool operating state;

当对比结果大于或等于预设阈值，报警反馈模块根据场景检测参数及第二振动数据确定故障信息，并发出报警信息，对机床进行调整。When the comparison result is greater than or equal to the preset threshold, the alarm feedback module determines the fault information according to the scene detection parameters and the second vibration data, and sends out an alarm message to adjust the machine tool.

本公开还提供一种数控机床设备，包括主机、三轴加速度传感器、数控装置和驱动装置；The present disclosure also provides a numerically controlled machine tool, including a host, a three-axis acceleration sensor, a numerically controlled device, and a driving device;

三轴加速度传感器设置于主机上，三轴加速度传感器设置为监测主机的运行状态；The three-axis acceleration sensor is set on the host, and the three-axis acceleration sensor is set to monitor the running state of the host;

驱动装置设置为驱动主机；The driving device is set as the driving host;

数控装置设置为与主机、三轴加速度传感器、驱动装置分别电连接；The numerical control device is set to be electrically connected to the host computer, the three-axis acceleration sensor and the driving device respectively;

其中，数控装置包括：数据采集模块，场景检测模块，数据处理模块，报警反馈模块，设备管理模块，供电电源，通讯模块以及Flash芯片；Among them, the numerical control device includes: data acquisition module, scene detection module, data processing module, alarm feedback module, equipment management module, power supply, communication module and Flash chip;

数据采集模块设置为获取三轴加速度传感器的反馈数据；The data acquisition module is set to obtain the feedback data of the three-axis acceleration sensor;

场景检测模块设置为检测或提供机床的操作状态；The scene detection module is configured to detect or provide the operating state of the machine tool;

数据处理模块设置为根据机床的操作状态，调用配置参数，对三轴加速度传感器的反馈数据进行数据预处理；The data processing module is set to call configuration parameters according to the operating state of the machine tool, and perform data preprocessing on the feedback data of the three-axis acceleration sensor;

报警反馈模块设置为对数据处理模块的预处理后的数据进行提取与计算，并分析计算结果，对应地进行报警和/或对机床进行调整；The alarm feedback module is set to extract and calculate the preprocessed data of the data processing module, analyze the calculation results, and correspondingly issue an alarm and/or adjust the machine tool;

设备管理模块设置为预设主机运行参数和人机交互；The device management module is set to preset host operating parameters and human-computer interaction;

供电电源设置为给所述数控装置供电；The power supply is set to supply power to the numerical control device;

通讯模块设置为传递数据及信号；The communication module is set to transmit data and signals;

Flash芯片设置为存储机床运行数据。The Flash chip is set to store the running data of the machine tool.

在一实施例中，报警反馈模块被设置为根据分析计算结果采取如下动作：提示报警，急停报警，断电，NC暂停，伺服轴锁定，进给保持，或，独立双回路急停触点。In one embodiment, the alarm feedback module is set to take the following actions according to the analysis and calculation results: prompt alarm, emergency stop alarm, power off, NC pause, servo axis lock, feed hold, or, independent dual-circuit emergency stop contact .

在一实施例中，通讯模块包括IO模块、以太网、总线协议、RS232、RS485、Ether Cat、Profinet、Profibus或RS422。In one embodiment, the communication module includes an IO module, Ethernet, bus protocol, RS232, RS485, Ether Cat, Profinet, Profibus or RS422.

本公开提供的一种机床机械部件动态保护方法及数控机床设备，能够实时监测机床的运行状态，同时实现对机床的机械部件的动态保护。当检测到故障信息时，快速做出反映，发出警示信息，在操作人员做出反应前，机床自身做出调整，避免故障发生；若故障已发生，机床能够及时停机，减小故障带来的损失。The present disclosure provides a method for dynamically protecting mechanical parts of a machine tool and equipment for a numerically controlled machine tool, which can monitor the running state of the machine tool in real time and simultaneously realize dynamic protection of the mechanical parts of the machine tool. When fault information is detected, it responds quickly and sends a warning message. Before the operator responds, the machine tool itself makes adjustments to avoid faults; if a fault has occurred, the machine tool can be stopped in time to reduce the damage caused by the fault loss.

附图说明Description of drawings

图1为一实施例提供的机床机械部件动态保护方法的流程示意图；Fig. 1 is a schematic flow chart of a method for dynamic protection of machine tool mechanical parts provided by an embodiment;

图2为一实施例提供的第一振动数据的数据平滑处理流程示意图；Fig. 2 is a schematic flow chart of the data smoothing process of the first vibration data provided by an embodiment;

图3为一实施例提供的第一振动数据的数据滤波处理流程示意图；Fig. 3 is a schematic flow chart of the data filtering process of the first vibration data provided by an embodiment;

图4为一实施例提供的数控机床设备的数控装置的内部结构示意图。Fig. 4 is a schematic diagram of the internal structure of a numerical control device of a numerical control machine tool provided by an embodiment.

具体实施方式Detailed ways

下面将参照相关附图对本公开进行描述。附图中给出了本公开的实施例。The present disclosure will be described below with reference to the related drawings. Embodiments of the present disclosure are shown in the drawings.

本公开实施例使用的技术术语或者科学术语应当为本公开所属领域内具有一般技能的人士所理解的通常意义。本公开实施例中使用的“第一”、“第二” 以及类似的词语并不表示任何顺序、数量或者重要性，而只是用来区分不同的组成部分。“包括”或者“包含”等类似的词语意指出现该词前面的元件或者物件涵盖出现在该词后面列举的元件或者物件及其等同，而不排除其他元件或者物件。“连接”或者“相连”等类似的词语并非限定于物理的或者机械的连接，而是可以包括电性的连接，不管是直接的还是间接的。“上”、“下”、“左”、“右”等仅用于表示相对位置关系，当被描述对象的绝对位置改变后，则该相对位置关系也可能相应地改变。The technical terms or scientific terms used in the embodiments of the present disclosure shall have the usual meanings understood by those skilled in the art to which the present disclosure belongs. "First", "second" and similar words used in the embodiments of the present disclosure do not indicate any order, quantity or importance, but are only used to distinguish different components. "Comprising" or "comprising" and similar words mean that the elements or items appearing before the word include the elements or items listed after the word and their equivalents, without excluding other elements or items. Words such as "connected" or "connected" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "Up", "Down", "Left", "Right" and so on are only used to indicate the relative positional relationship. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

图1为一实施例提供的机床机械部件动态保护方法的流程示意图；为解决机床在发生故障后，无法及时调整，造成机床撞机的重大事故的问题，如图1所示，本实施例提供的机床机械部件动态保护方法，包括：Fig. 1 is a schematic flow diagram of the dynamic protection method for machine tool mechanical parts provided by an embodiment; in order to solve the problem that the machine tool cannot be adjusted in time after a failure occurs, causing a major accident of the machine tool collision, as shown in Fig. 1, this embodiment provides A dynamic protection method for machine tool mechanical parts, including:

实时监测机床运行状态，获取机床当前运行场景下的配置参数，所述配置参数至少包括预设阈值、高通值、低通值、延时参数、换算个数中的一个或多个。由于机床的运行场景不同，加工对象不同，使用的加工工艺不同，在不同的加工场景下，在加工过程中会产生不同的加工故障。根据不同场景下的不同加工故障，对配置参数进行限定及修改，可及时更改机床的报警条件，匹配不同的场景，及时发现机床的故障并做出相应的调整。Monitor the running state of the machine tool in real time, and acquire configuration parameters in the current running scene of the machine tool, the configuration parameters at least including one or more of preset thresholds, high-pass values, low-pass values, delay parameters, and conversion numbers. Due to the different operating scenarios of the machine tool, different processing objects, and different processing techniques used, different processing faults will occur during the processing under different processing scenarios. According to different processing faults in different scenarios, the configuration parameters are limited and modified, and the alarm conditions of the machine tool can be changed in time to match different scenarios, and the faults of the machine tool can be found in time and corresponding adjustments can be made.

在机床运行过程中，三轴加速度传感器实时采集机床主轴的空间加速度，并通过通讯模块，将检测到的数据实时反馈至数据采集模块，在数据采集模块中暂存，当数据处理模块需要数据时，数据处理模块可从数据采集模块获取三轴加速度传感器反馈的数据。数据处理模块获取三轴加速度传感器反馈的数据作为第一振动数据，并对所述第一振动数据依次进行数据平滑处理和数据滤波处理，得到第二振动数据。除了使用三轴加速度传感器检测机床主轴空间加速度，进行X轴向、Y轴向、Z轴向的三轴向数据的分析，也可以从X轴向、Y轴向、Z轴向这三个轴向数据中选取其中的一个或两个数据进行分析。此外，除了检测机床主轴的加速度数据，也可以检测机床主轴的其他参数，比如检测温度，若机床主轴温度过高，超过正常范围，主轴容易发生变形，导致机床机械损伤，造成机床加工事故，需要及时排查故障运营进行调整。During the operation of the machine tool, the three-axis acceleration sensor collects the spatial acceleration of the machine tool spindle in real time, and feeds back the detected data to the data acquisition module in real time through the communication module, and temporarily stores it in the data acquisition module. When the data processing module needs data , the data processing module can acquire the data fed back by the three-axis acceleration sensor from the data acquisition module. The data processing module obtains the data fed back by the three-axis acceleration sensor as the first vibration data, and sequentially performs data smoothing and data filtering processing on the first vibration data to obtain second vibration data. In addition to using the three-axis acceleration sensor to detect the spatial acceleration of the machine tool spindle and analyze the three-axis data of the X-axis, Y-axis, and Z-axis, it is also possible to analyze the three-axis data from the X-axis, Y-axis, and Z-axis. Select one or two data from the data for analysis. In addition, in addition to detecting the acceleration data of the machine tool spindle, other parameters of the machine tool spindle can also be detected, such as the detection temperature. If the temperature of the machine tool spindle is too high and exceeds the normal range, the spindle is prone to deformation, causing mechanical damage to the machine tool and causing machine tool processing accidents. Troubleshoot and adjust operations in a timely manner.

数据处理模块可根据所述配置参数，对所述第二振动数据进行计算整合，提取特征数据，所述特征数据可反应机床的运状况；将所述特征数据与所述预设阈值进行对比，得到对比结果。The data processing module can calculate and integrate the second vibration data according to the configuration parameters to extract characteristic data, and the characteristic data can reflect the operation status of the machine tool; compare the characteristic data with the preset threshold, Get the comparison result.

根据所述对比结果，确定报警方式，和/或对机床进行调整。According to the comparison result, the alarm mode is determined, and/or the machine tool is adjusted.

其中，所述特征数据包括对所述第二振动数进行计算得到的峰峰值、平均值、均方根值和域值中的一种或多种。获取所述特征参数进行对比判断时，不论特征参数包含一个或多个特征值，只要有一个特征值的对比结果判定机床运行出现异常，机床启用报警反馈模块，发送报警信号，并进行相应调整。Wherein, the feature data includes one or more of peak-to-peak value, average value, root mean square value and threshold value obtained by calculating the second vibration number. When obtaining the characteristic parameters for comparison and judgment, regardless of whether the characteristic parameters contain one or more characteristic values, as long as there is a comparison result of one characteristic value to determine that the machine tool is running abnormally, the machine tool activates the alarm feedback module, sends an alarm signal, and makes corresponding adjustments.

数控机床的存储器中存储有车削、铣削、自动换刀、磨削等基础操作的指令，根据产品加工要求，对这些指令进行编程，再将编程输入至机床，机床就能实行相应的操作，进行生产加工。故而机床的运行场景相对固定，根据指令进行机床的运行场景包括：The memory of the CNC machine tool stores instructions for basic operations such as turning, milling, automatic tool change, and grinding. According to product processing requirements, program these instructions, and then input the programming to the machine tool, and the machine tool can perform corresponding operations. Production and processing. Therefore, the operating scene of the machine tool is relatively fixed, and the operating scene of the machine tool according to the instruction includes:

在一实施例中，数据处理模块获取的三轴加速度传感器反馈的数据过于繁杂，需要对这些数据进行相应的数据处理，从而去除数据中的干扰，筛选出对判断机床振动情况有用的信息。数据处理模块对第一振动数据进行数据处理方法包括数据平滑处理和数据滤波处理。图2为一实施例提供的第一振动数据的数据平滑处理流程示意图，如图2所示，本实施例提供的数据处理模块对所述第一振动数据进行数据平滑处理的具体步骤包括:In one embodiment, the data fed back by the three-axis acceleration sensor acquired by the data processing module is too complicated, and corresponding data processing needs to be performed on these data, so as to remove the interference in the data and screen out useful information for judging the vibration of the machine tool. The data processing module performs data processing methods on the first vibration data, including data smoothing processing and data filtering processing. Fig. 2 is the schematic flow chart of the data smoothing processing of the first vibration data provided by an embodiment, as shown in Fig. 2, the specific steps that the data processing module provided by the present embodiment carries out data smoothing processing to the first vibration data include:

获取机床的三轴加速度传感器反馈的X轴向、Y轴向、Z轴向的三轴向数据，其中，一个三轴向数据为一组数据，采集连续或不连续的3组数据，将该3组数据与采集这3组数据之前已经采集的61组数据拼接为64组数据，作为第一振动数据；Obtain the three-axis data of the X-axis, Y-axis, and Z-axis fed back by the three-axis acceleration sensor of the machine tool. Among them, one three-axis data is a set of data, and three sets of continuous or discontinuous data are collected. The 3 sets of data and the 61 sets of data collected before these 3 sets of data are spliced into 64 sets of data as the first vibration data;

对第一振动数据中的X轴向数据、Y轴向数据、Z轴向数据分别求平均数，得到X轴向振动数据的平均数、Y轴向振动数据的平均数、Z轴向振动数据的平均数；将第一振动数据按照X轴向、Y轴向、Z轴向组成矩阵，并对X轴向振动数据的平均数、Y轴向振动数据的平均数、Z轴向振动数据的平均数做矩阵相减，得到三轴的差值矩阵；Calculate the average of the X-axis data, Y-axis data, and Z-axis data in the first vibration data to obtain the average of the X-axis vibration data, the average of the Y-axis vibration data, and the Z-axis vibration data The average number; the first vibration data is formed into a matrix according to the X-axis, Y-axis, and Z-axis, and the average number of the X-axis vibration data, the average number of the Y-axis vibration data, and the Z-axis vibration data The average is subtracted from the matrix to obtain the three-axis difference matrix;

将第一振动数据转化为余弦函数，得到64组数据中每组数据的余弦函数值：根据所述差值矩阵及所述余弦函数，进行窗函数处理，将对应的同一组三轴向数据的所述差值矩阵与其对应的余弦函数值相乘，得到的乘积即为窗函数数值。Convert the first vibration data into a cosine function to obtain the cosine function value of each set of data in the 64 sets of data: perform window function processing according to the difference matrix and the cosine function, and convert the corresponding three-axis data of the same set The difference matrix is multiplied by its corresponding cosine function value, and the obtained product is the value of the window function.

其中，在本实施例中，所述余弦函数公式为：Wherein, in the present embodiment, the cosine function formula is:

W[j]＝0.5-0.48cos((2πj)/(j-1))+0.02cos((4πj)/(j-1))W[j]＝0.5-0.48cos((2πj)/(j-1))+0.02cos((4πj)/(j-1))

由于三轴加速度传感器反馈的数据极其庞杂，且时间间隔较久的数据对机床振动情况的判断有所干扰，同时出于数据处理模块处理数据的速度的考虑，数据处理模块进行数据处理分析时，一般选取最新的64组数据进行数据处理。在一个可行的实施方式中，数据处理模块每次从数据采集模块获取3组数据，并且和之前的61组数据拼接为64组数据X[64]，Y[64]，Z[64]。Since the data fed back by the three-axis acceleration sensor is extremely complex, and the data with a long time interval interferes with the judgment of the vibration of the machine tool, and at the same time, considering the speed of data processing by the data processing module, when the data processing module performs data processing and analysis, Generally, the latest 64 sets of data are selected for data processing. In a feasible implementation, the data processing module acquires 3 sets of data from the data acquisition module each time, and splices with the previous 61 sets of data into 64 sets of data X[64], Y[64], Z[64].

对获取到的X[64]，Y[64]，Z[64]进行求平均数处理：Perform averaging processing on the obtained X[64], Y[64], Z[64]:

在将X[64]，Y[64]，Z[64]组成矩阵，与X[64]对应的平均数TX，与Y[64]对应的平均数TY，与Z[64]对应的平均数TZ做矩阵相减：When X[64], Y[64], Z[64] are formed into a matrix, the average number TX corresponding to X[64], the average number TY corresponding to Y[64], and the average number corresponding to Z[64] TZ does matrix subtraction:

得到的差值矩阵KX[n]、KY[n]、KZ[n]能够明显的获取到数据的乖离程度。The obtained difference matrix KX[n], KY[n], KZ[n] can clearly obtain the deviation degree of the data.

将第一振动数据全部转换为余弦函数：Convert the first vibration data all to a cosine function:

取最后一个检测时刻之前n个数据W[n]。Take n data W[n] before the last detection moment.

对K[n]进行窗函数处理，处理公式为：Perform window function processing on K[n], the processing formula is:

得到的窗函数数值SX[n]、SY[n]、SZ[n]，可以强化最新的数据在该组数据中的影响力，弱化老数据的影响。The obtained window function values SX[n], SY[n], and SZ[n] can strengthen the influence of the latest data in the set of data and weaken the influence of old data.

图3为一实施例提供的第一振动数据的数据滤波处理流程示意图，如图3所示，本实施例中数据处理模块对所述第一振动数据进行数据平滑处理后，得到中间处理数据，再进行数据滤波处理得到第二振动数据，具体步骤包括：Fig. 3 is a schematic diagram of the data filtering process flow of the first vibration data provided by an embodiment. As shown in Fig. 3, the data processing module in this embodiment performs data smoothing processing on the first vibration data to obtain intermediate processed data, Then perform data filtering processing to obtain the second vibration data, and the specific steps include:

将所述中间振动数据通过傅里叶变换，得到中间振动数据频域数据；Transforming the intermediate vibration data through Fourier transform to obtain frequency domain data of the intermediate vibration data;

根据所述配置参数，对中间振动数据频域数据进行高低通滤波，得到滤波后带通数据；According to the configuration parameters, high- and low-pass filtering is performed on the frequency-domain data of the intermediate vibration data to obtain filtered band-pass data;

将所述带通数据进行傅里叶逆变换，得到第二振动数据。performing an inverse Fourier transform on the bandpass data to obtain second vibration data.

在一个可行的实施方式中，将S[n]通过傅里叶变换，获取到频域数据FX[n]，FY[n]，FZ[n]，根据所述配置参数，对频域数据FX[n]，FY[n]，FZ[n]，进行高低通滤波，得到滤波后带通数据，将所述带通数据进行傅里叶逆变换，得到第二振动数据。例如数据处理模块获取的配置参数包括预设阈值10，高通300，低通800，报警打开，急停打开，报警等级，延时800毫秒。根据所述配置参数，将频率<300或者频率>800的数据设置为0，保留300到800之间的带通数据，并对所述带通数据做逆向傅里叶变换得到AX[n]，AY[n]，AZ[n]。若在后续判断过程中，确定需要报警，报警时间设置为800毫秒。若数据处理模块获取的配置参数包括预设阈值50，高通10，低通1600，报警打开，急停关闭，换算个数为10，将频率<10或者频率>1600的数据设置为0，保留10到1600之间的带通数据生成，并做傅里叶逆变换得到AX[n]，AY[n]，AZ[n]。经过滤波处理的数据能更直观的反映机床振动信息，滤除干扰因素。In a feasible implementation, S[n] is transformed through Fourier to obtain frequency domain data FX[n], FY[n], FZ[n], and according to the configuration parameters, the frequency domain data FX [n], FY[n], FZ[n], perform high and low-pass filtering to obtain filtered band-pass data, and perform inverse Fourier transform on the band-pass data to obtain second vibration data. For example, the configuration parameters obtained by the data processing module include a preset threshold of 10, a high pass of 300, a low pass of 800, an alarm on, an emergency stop on, an alarm level, and a delay of 800 milliseconds. According to the configuration parameters, set the data with frequency <300 or frequency>800 to 0, keep the band-pass data between 300 and 800, and perform an inverse Fourier transform on the band-pass data to obtain AX[n], AY[n], AZ[n]. If in the subsequent judgment process, it is determined that an alarm is required, the alarm time is set to 800 milliseconds. If the configuration parameters acquired by the data processing module include preset threshold 50, high pass 10, low pass 1600, alarm on, emergency stop off, conversion number is 10, set the data with frequency <10 or frequency >1600 to 0, and keep 10 The bandpass data between 1600 and 1600 is generated, and inverse Fourier transform is performed to obtain AX[n], AY[n], AZ[n]. The filtered data can more intuitively reflect the vibration information of the machine tool and filter out the interference factors.

获取第二振动数据后，第二振动数据包含多种信息，需要根据所述配置参数，对所述第二振动数据进行计算整合，结合机床运行场景下的故障及表现，从所述第二振动数据中提取与机床运行场景的故障及表现相匹配的特征参数，可以更直观且迅速的判断机床的故障情况。获取特征参数的步骤为：After the second vibration data is acquired, the second vibration data contains a variety of information, and the second vibration data needs to be calculated and integrated according to the configuration parameters, and combined with the fault and performance in the machine tool operation scene, from the second vibration The characteristic parameters that match the faults and performance of the machine tool operation scene are extracted from the data, so that the fault condition of the machine tool can be judged more intuitively and quickly. The steps to obtain feature parameters are:

当配置参数对应的场景为重点刀具监控场景时，特征参数包括平均值和均方根和峰峰值；When the scene corresponding to the configuration parameters is a key tool monitoring scene, the characteristic parameters include the average value, root mean square and peak value;

在本实施例中中，异常撞机指机床处于手动或者自动模式进行加工时，机床处于快速进给或钝速等空载运行状态时发生非正常碰撞。机床进入异常撞机场景可通过对机床***进行设计，输出对应状态的信号以自动切换至该场景模式。在异常撞机模式下，按照本实施例中的算法进行计算，计算后的结果超过预设阈值时即输出报警，该场景下报警反馈模块直接控制机床急停。In this embodiment, an abnormal collision refers to an abnormal collision that occurs when the machine tool is in a no-load running state such as fast feed or blunt speed when the machine tool is in manual or automatic mode for processing. When the machine tool enters the abnormal collision scene, the machine tool system can be designed to output the corresponding state signal to automatically switch to the scene mode. In the abnormal collision mode, the calculation is performed according to the algorithm in this embodiment. When the calculated result exceeds the preset threshold, an alarm is output. In this scenario, the alarm feedback module directly controls the emergency stop of the machine tool.

切削过载，指机床在自动模式下执行G01、G02等机床切削动作，此时让机床输出该场景的相应IO信号，进入切削过载场景。由于机床本身主轴是允许过载的，但是不允许长时间的过载，且切削过程中刀具始终与工件处于接触状态，所以该场景下需要监控的是当前持续性的动能状态，多采用能量的计算方法，如本实施例中进行均方根计算。当计算后的整体数据值达到预设阈值时，即认为目前处于过载状态，需要报警停机以保护工件或主轴，此时报警反馈模块会触发NC暂停动作或者急停报警动作。Cutting overload means that the machine tool executes G01, G02 and other machine cutting actions in automatic mode. At this time, let the machine tool output the corresponding IO signal of the scene and enter the cutting overload scene. Since the main shaft of the machine tool itself is allowed to be overloaded, but it is not allowed to be overloaded for a long time, and the tool is always in contact with the workpiece during the cutting process, so what needs to be monitored in this scenario is the current continuous kinetic energy state, and energy calculation methods are often used , the root mean square calculation is performed as in this embodiment. When the calculated overall data value reaches the preset threshold, it is considered to be in an overload state, and an alarm shutdown is required to protect the workpiece or the spindle. At this time, the alarm feedback module will trigger the NC pause action or emergency stop alarm action.

异常换刀，是指各类换刀机构在换刀时将主轴和刀库的到进行交换的动作，该过程中容易因位置偏离、松动等原因造成打刀、掉刀、卡刀等情况，换刀动作是机床上一个最常用但特殊的动作过程，机床设有相应的IO信号触发异常换刀场景。由于换刀机构直接针对主轴上的刀具进行操作，所以当发生异常时，传感器检测到的数据会普遍较大，在设置预设阈值时也会相应的提高，但是整个换刀过程由于是连贯动作，需要对接收的数据进行程度的区分，触碰到低边界时触发NC暂停，完成动作；触发高边界时报警反馈模块触发急停报警，保护主轴不受损伤。Abnormal tool change refers to the action of various tool change mechanisms to exchange the spindle and the tool magazine during tool change. During this process, it is easy to cause the tool to hit, drop, or jam due to position deviation and looseness. The tool change action is the most commonly used but special action process on the machine tool. The machine tool is equipped with corresponding IO signals to trigger abnormal tool change scenes. Since the tool change mechanism operates directly on the tool on the spindle, when an abnormality occurs, the data detected by the sensor will generally be large, and the preset threshold will be increased accordingly. However, the entire tool change process is a coherent action. , It is necessary to distinguish the degree of the received data, trigger NC pause when the low boundary is touched, and complete the action; when the high boundary is triggered, the alarm feedback module triggers an emergency stop alarm to protect the spindle from damage.

重切削是指大切削量的加工，此时机床主轴的负载较大，可以明显感觉到机床的强烈振动。如需执行该工序，机床需要单独的进行监控，机床可通过读取机床***当前刀号或者特殊的指令(如M代码或者G代码)切换至该场景。相比于普通切削过载，重切削场景下监控的数据更加偏向整体，所以需要放大采集数据样本的数量，这样就能反映一个更宏观的状态。该场景超过边界时，报警反馈模块一般执行触发NC暂停指令。Heavy cutting refers to processing with a large amount of cutting. At this time, the load of the machine tool spindle is relatively large, and the strong vibration of the machine tool can be clearly felt. To perform this process, the machine tool needs to be monitored separately. The machine tool can switch to this scene by reading the current tool number of the machine tool system or special instructions (such as M code or G code). Compared with ordinary cutting overload, the monitoring data in the heavy cutting scene is more biased towards the whole, so it is necessary to enlarge the number of collected data samples, so as to reflect a more macroscopic state. When the scene exceeds the boundary, the alarm feedback module generally executes and triggers the NC pause command.

各伺服轴磨损，是指丝杠、导轨等运动机械部件长期使用后的损耗。由于该损耗是非常小的，所以切换至各伺服轴磨损场景需要规定一个固定的动作循环。机床先通过指令调用该场景，再通过积分累计的方法来计算整体的数据。当数据的值达到预设阈值时，该场景下报警反馈模块即可根据程度触发NC暂停或者提醒报警，避免运动部件朝更坏的方向发展。The wear of each servo shaft refers to the loss of moving mechanical parts such as screw and guide rail after long-term use. Since this loss is very small, switching to each servo axis wear scenario requires a fixed action cycle. The machine tool first invokes the scene through instructions, and then calculates the overall data through the method of integral accumulation. When the value of the data reaches the preset threshold, the alarm feedback module in this scenario can trigger the NC to suspend or remind the alarm according to the degree, so as to prevent the moving parts from developing in a worse direction.

重复加工监控，是指操作人员在不知情或遗忘的情况下对已经加工完成的工件重新进行加工，从而损坏工件的情况。在重复加工监控场景下，在开始进行切削动作时，实时监控机床的负载，利用预设阈值进行判断。不能低于预设阈值，如果低于该值即认为是已经加工过的工件，应立即急停报警。Repeated processing monitoring refers to the situation where the operator re-processes the workpiece that has been processed without knowing or forgetting, thus damaging the workpiece. In the repetitive processing monitoring scenario, when the cutting action is started, the load of the machine tool is monitored in real time, and the preset threshold is used for judgment. It cannot be lower than the preset threshold value. If it is lower than this value, it is considered as a workpiece that has been processed, and an emergency stop alarm should be issued immediately.

自适应控制场景，该场景针对加工中的特殊刀具或者重要工艺，通过监控切削负载的变化，设置更加灵活的计算方法进行计算，可将多种计算方法混合使用。此时监控的预设阈值不作为报警的触发条件，而是直接控制机床的进给倍率，如负载变大时降低进给倍率，负载减小时提升进给倍率，从而提升机床加工时的效率。Adaptive control scenario, this scenario is aimed at special tools or important processes in processing, by monitoring the change of cutting load, setting a more flexible calculation method for calculation, and multiple calculation methods can be used in combination. At this time, the preset threshold value monitored is not used as the trigger condition for the alarm, but directly controls the feed override of the machine tool, such as reducing the feed override when the load increases, and increasing the feed override when the load decreases, thereby improving the efficiency of the machine tool during processing.

特征参数的提取方式有多种，在一个进一步的实施方式中，所述特征参数的提取方式包括：There are many ways to extract the feature parameters. In a further embodiment, the way to extract the feature parameters includes:

所述峰峰值的获取方式为根据第二振动数据组的波形图，计算波形图中的波峰波谷值。The peak-to-peak value is obtained by calculating the peak-to-valley values in the waveform diagram according to the waveform diagram of the second vibration data set.

所述平均值的计算方法为获取第一振动数据，将同一组X轴向数据、Y轴向数据、Z轴向数据按照向量和的计算方法进行计算，得到该组数据的向量和；并与相邻时间采集的两组三轴向数据的向量和进行平均数计算，得到所述平均值。具体的，将第二振动数据中同一时间对应的时域数据AX[n]，AY[n]，AZ[n]筛选出来，将筛选出来的AX[n]，AY[n]，AZ[n]按照向量和的计算方法进行计算，将三个数据分别进行平方并乘以同一个参数后相加，之后进行开方，得到开方后的值，具体计算公式为：The calculation method of the average value is to obtain the first vibration data, calculate the same group of X-axis data, Y-axis data, and Z-axis data according to the calculation method of vector sum, and obtain the vector sum of this group of data; and The vector sum of two sets of triaxial data collected at adjacent times is calculated to obtain the average value. Specifically, the time domain data AX[n], AY[n], AZ[n] corresponding to the same time in the second vibration data are screened out, and the screened AX[n], AY[n], AZ[n] ] According to the calculation method of vector sum, the three data are squared and multiplied by the same parameter and added, and then the square root is performed to obtain the value after the square root. The specific calculation formula is:

根据时间可从第二振动数据组中筛选出若干组同一时间对应的时域数据AX[n]，AY[n]，AZ[n]。按照上述的计算方法获取若干个按照向量和计算方法计算出的值，对计算出来的若干个值的进行平均数计算，得到所述平均值。Several groups of time-domain data AX[n], AY[n], AZ[n] corresponding to the same time can be screened out from the second vibration data group according to time. According to the above calculation method, several values calculated according to the vector sum calculation method are obtained, and the average value of the calculated several values is calculated to obtain the average value.

所述均方根的计算方法为获取第一振动数据，对第一振动数据中，以时间基准向后连续选取设定数量的以连续3组为基本单元的三轴向数据，每连续3组按照X轴向数据、Y轴向数据、Z轴向数据分别进行均方根的计算，再获取设定数量的基本单元的均方根进行均值计算。具体的，对第二振动数据中的X轴向数据组、Y轴向数据组、Z轴向数据组三个数据组选取数据进行均方根的计算公式为：The calculation method of the root mean square is to obtain the first vibration data. For the first vibration data, a set number of three-axis data with 3 consecutive groups as the basic unit is continuously selected backwards with a time reference. Every 3 consecutive groups Calculate the root mean square according to the X-axis data, Y-axis data, and Z-axis data, and then obtain the root mean square of a set number of basic units to calculate the mean value. Specifically, the formula for calculating the root mean square of the data selected from the three data groups of the X-axis data group, the Y-axis data group, and the Z-axis data group in the second vibration data is:

可从第二振动数据中选取连续三组数据设为基本单元，可获取k个基本单元，包括BX[0]-BX[k-1]，BY[0]-BY[k-1]，BZ[0]-BZ[k-1]。对得到的k个基本单元的均方根进行平均数处理：Three consecutive sets of data can be selected from the second vibration data as the basic unit, and k basic units can be obtained, including BX[0]-BX[k-1], BY[0]-BY[k-1], BZ [0]-BZ[k-1]. The root mean square of the obtained k basic units is averaged:

均方根值平均值SX、SY、SZ，用于比较判断，分析三个方向中的异常数据，从而判断出机床上是否存在磨损或故障，并及时进行报警。Root mean square value SX, SY, SZ are used for comparison and judgment, analyzing abnormal data in three directions, so as to judge whether there is wear or failure on the machine tool, and give an alarm in time.

所述域值的计算方法为获取第二振动数据的波动范围值。The calculation method of the threshold value is to obtain the fluctuation range value of the second vibration data.

在根据所述配置参数及所述第二振动数据，获得判断所需的特征数据后，将所述特征数据与所述预设阈值进行对比，根据所述对比结果，确定报警方式，根据配置参数确定报警时间，对机床进行调整，具体判断步骤包括：After obtaining the characteristic data required for judgment according to the configuration parameters and the second vibration data, compare the characteristic data with the preset threshold value, determine the alarm mode according to the comparison result, and determine the alarm mode according to the configuration parameters Determine the alarm time and adjust the machine tool. The specific judgment steps include:

若所述对比结果小于所述预设阈值，则机床维持所述机床操作状态；If the comparison result is less than the preset threshold, the machine tool maintains the machine tool operating state;

若所述对比结果大于或等于所述预设阈值，所述报警反馈模块根据所述场景检测参数及所述第二振动数据确定故障信息，并发出报警信息，对机床进行调整。If the comparison result is greater than or equal to the preset threshold, the alarm feedback module determines fault information according to the scene detection parameters and the second vibration data, and sends out an alarm message to adjust the machine tool.

图4为一实施例提供的数控机床设备的数控装置的内部结构示意图。如图4所示，与上述任一实施例相对应的，本实施例还提供一种所述数控机床设备，包括主机、三轴加速度传感器、数控装置和驱动装置。Fig. 4 is a schematic diagram of the internal structure of a numerical control device of a numerical control machine tool provided by an embodiment. As shown in FIG. 4 , corresponding to any of the above-mentioned embodiments, this embodiment also provides the numerically controlled machine tool equipment, including a host computer, a three-axis acceleration sensor, a numerically controlled device, and a driving device.

为在预先不知道物体运动方向的场合下，检测机床的振动情况，且检测工具的体积、重量不宜过大，同时还需要能够全面准确反映物体的运动性质，使用三轴加速度传感器对机床的运行状况进行检测。所述三轴加速度传感器设置于所述主机上，三轴加速度传感器设置为监测所述主机的运行状态。In order to detect the vibration of the machine tool when the motion direction of the object is not known in advance, and the volume and weight of the detection tool should not be too large, and it is also necessary to fully and accurately reflect the motion properties of the object, a three-axis acceleration sensor is used to monitor the operation of the machine tool. condition is checked. The three-axis acceleration sensor is set on the host, and the three-axis acceleration sensor is set to monitor the running state of the host.

所述驱动装置设置为驱动所述主机。The drive device is configured to drive the host.

所述数控装置设置为与所述主机、所述三轴加速度传感器、所述驱动装置分别电连接。所述数控装置中预先根据设置有多组基本指令，如M开头的指令代表加工程序开始及结束，G开头的指令代表切削指令。通过对这些指令进行编辑得到加工程序，机床执行相应加工程序，进行生产加工。The numerical control device is configured to be electrically connected to the host computer, the three-axis acceleration sensor, and the driving device, respectively. There are multiple groups of basic instructions set in advance in the numerical control device, such as instructions beginning with M represent the start and end of a machining program, and instructions beginning with G represent cutting instructions. The processing program is obtained by editing these instructions, and the machine tool executes the corresponding processing program for production and processing.

其中，所述数控装置包括：数据采集模块，场景检测模块，数据处理模块，报警反馈模块，设备管理模块，供电电源，通讯模块以及Flash芯片。Wherein, the numerical control device includes: a data acquisition module, a scene detection module, a data processing module, an alarm feedback module, an equipment management module, a power supply, a communication module and a Flash chip.

数据采集模块101设置为获取三轴加速度传感器的反馈数据；The data collection module 101 is configured to obtain the feedback data of the three-axis acceleration sensor;

场景检测模块106设置为检测或提供机床的操作状态；The scene detection module 106 is configured to detect or provide the operating state of the machine tool;

数据处理模块105设置为根据机床的操作状态，调用配置参数，对三轴加速度传感器的反馈数据进行数据预处理；The data processing module 105 is configured to call configuration parameters according to the operating state of the machine tool, and perform data preprocessing on the feedback data of the three-axis acceleration sensor;

报警反馈模块103设置为对数据处理模块105的预处理后的数据进行提取与计算，并分析计算结果，对应地进行报警和/或对机床进行调整；The alarm feedback module 103 is configured to extract and calculate the preprocessed data of the data processing module 105, and analyze the calculation results, and report to the police and/or adjust the machine tool accordingly;

设备管理模块102设置为预设主机运行参数和人机交互；所述设备管理模块102可外接设备，显示数据，便于管理人员更直观的判断设备振动状态；The device management module 102 is set to preset host operating parameters and human-computer interaction; the device management module 102 can be connected to external devices to display data, which is convenient for managers to judge the vibration state of the device more intuitively;

供电电源108设置为给所述数控装置供电；The power supply 108 is configured to supply power to the numerical control device;

通讯模块104设置为传递数据及信号；The communication module 104 is configured to transmit data and signals;

Flash芯片107设置为存储机床运行数据，包括配置参数、日志数据、设备管理数据等。The Flash chip 107 is configured to store machine tool operation data, including configuration parameters, log data, equipment management data, and the like.

所述数控机床设备中，由于机床各项故障带来的后果不同，可以根据故障的具体表现及其造成的后果，设定多种报警形式，确保机床的运行效率。所述数控机床设备中，所述报警反馈模块103被设置为根据分析计算结果采取如下动作：提示报警，急停报警，断电，NC暂停，伺服轴锁定，进给保持，或，独立双回路急停触点。In the numerical control machine tool equipment, since various failures of the machine tool have different consequences, various alarm forms can be set according to the specific manifestations of the failure and the consequences caused, so as to ensure the operating efficiency of the machine tool. In the CNC machine tool, the alarm feedback module 103 is set to take the following actions according to the analysis and calculation results: prompt alarm, emergency stop alarm, power failure, NC pause, servo axis lock, feed hold, or, independent double loop Emergency stop contact.

数控机床通过通讯模块104进行机床各部件之间的数据交互，通讯模块104的设置可根据机床的各项参数及运行场景进行配置，所述通讯模块104至少包括：IO模块、以太网、总线协议、RS232、RS485、Ether Cat、Profinet、Profibus或RS422。The CNC machine tool performs data interaction between various parts of the machine tool through the communication module 104. The setting of the communication module 104 can be configured according to various parameters and operating scenarios of the machine tool. The communication module 104 at least includes: IO module, Ethernet, bus protocol , RS232, RS485, Ether Cat, Profinet, Profibus or RS422.

Claims

一种机床机械部件动态保护方法，包括：A method for dynamic protection of mechanical parts of a machine tool, comprising:

获取机床在当前运行场景下的配置参数，所述配置参数包括预设阈值、高通值、低通值、延时参数和换算个数中的一个或多个；Obtain the configuration parameters of the machine tool in the current operating scenario, the configuration parameters include one or more of preset thresholds, high-pass values, low-pass values, delay parameters and conversion numbers;

获取机床的三轴加速度传感器反馈的数据作为第一振动数据，并对所述第一振动数据依次进行数据平滑处理和数据滤波处理，得到第二振动数据；Obtaining the data fed back by the three-axis acceleration sensor of the machine tool as the first vibration data, and sequentially performing data smoothing and data filtering processing on the first vibration data to obtain second vibration data;

根据所述配置参数，对所述第二振动数据进行计算，获得特征数据，将所述特征数据与所述预设阈值进行对比，得到对比结果；calculating the second vibration data according to the configuration parameters to obtain feature data, and comparing the feature data with the preset threshold to obtain a comparison result;

根据所述对比结果，确定报警方式，和/或对机床进行调整；According to the comparison result, determine the alarm mode, and/or adjust the machine tool;

其中，所述特征数据包括对所述第二振动数进行计算得到的峰峰值、平均值、均方根值和域值中的一种或多种。Wherein, the feature data includes one or more of peak-to-peak value, average value, root mean square value and threshold value obtained by calculating the second vibration number.
根据权利要求1所述的机床机械部件动态保护方法，其中，机床的运行场景包括：The method for dynamic protection of machine tool mechanical parts according to claim 1, wherein the operating scenarios of the machine tool include:

快速进给场景、切削场景、换刀场景、重复加工监控场景、重点刀具监控场景、伺服轴磨损监控场景、重切削场景或自适应控制场景。Rapid feed scene, cutting scene, tool change scene, repetitive processing monitoring scene, key tool monitoring scene, servo shaft wear monitoring scene, heavy cutting scene or adaptive control scene.
根据权利要求1所述的机床机械部件动态保护方法，其中，所述数据平滑处理的步骤包括：The method for dynamic protection of machine tool mechanical parts according to claim 1, wherein the step of smoothing data processing comprises:

获取机床的三轴加速度传感器反馈的X轴向、Y轴向、Z轴向的三轴向数据，其中，一个三轴向数据为一组数据，采集3组数据，将该3组数据与采集这3组数据之前已经采集的61组数据拼接为64组数据，作为第一振动数据；Acquire the three-axis data of the X-axis, Y-axis, and Z-axis fed back by the three-axis acceleration sensor of the machine tool. Among them, one three-axis data is a set of data, collect 3 sets of data, and combine the 3 sets of data with the collected The 61 sets of data that have been collected before these 3 sets of data are spliced into 64 sets of data as the first vibration data;

对第一振动数据中的X轴向数据、Y轴向数据、Z轴向数据分别求平均数，得到X轴向振动数据的平均数、Y轴向振动数据的平均数、Z轴向振动数据的平均数；将第一振动数据按照X轴向、Y轴向、Z轴向组成矩阵，并对X轴向振动数据的平均数、Y轴向振动数据的平均数、Z轴向振动数据的平均数做矩阵相减，得到三轴向的差值矩阵；Calculate the average of the X-axis data, Y-axis data, and Z-axis data in the first vibration data to obtain the average of the X-axis vibration data, the average of the Y-axis vibration data, and the Z-axis vibration data The average number; the first vibration data is formed into a matrix according to the X-axis, Y-axis, and Z-axis, and the average number of the X-axis vibration data, the average number of the Y-axis vibration data, and the Z-axis vibration data The average is subtracted from the matrix to obtain the difference matrix of the three axes;

将第一振动数据转化为余弦函数，得到64组数据中每组数据的余弦函数值：Convert the first vibration data into a cosine function, and obtain the cosine function value of each group of data in the 64 groups of data:

根据所述差值矩阵及所述余弦函数，进行窗函数处理，将对应的同一组三轴向数据的所述差值矩阵与其对应的余弦函数值相乘，得到的乘积即为窗函数数值。Perform window function processing according to the difference matrix and the cosine function, and multiply the difference matrix of the corresponding same group of three-axis data with the corresponding cosine function value, and the obtained product is the value of the window function.
根据权利要求1所述的机床机械部件动态保护方法，其中，所述数据滤波处理的步骤包括：The method for dynamic protection of machine tool mechanical parts according to claim 1, wherein the step of data filtering comprises:

将所述窗函数数值进行傅里叶变换，得到窗函数数值频域数据；Performing Fourier transform on the window function value to obtain window function value frequency domain data;

根据所述配置参数，对窗函数数值频域数据进行高低通滤波，得到带通数据；According to the configuration parameters, high and low pass filtering is performed on the window function numerical frequency domain data to obtain bandpass data;

将所述带通数据进行傅里叶逆变换，得到第二振动数据。performing an inverse Fourier transform on the bandpass data to obtain second vibration data.
根据权利要求1所述的机床机械部件动态保护方法，其中，根据所述配置参数，对所述第二振动数据进行计算，获得特征数据的步骤中：The dynamic protection method for machine tool mechanical parts according to claim 1, wherein, in the step of calculating the second vibration data and obtaining characteristic data according to the configuration parameters:

当配置参数对应的场景为异常撞机场景时，特征参数包括平均值、峰峰值；When the scene corresponding to the configuration parameters is an abnormal collision scene, the characteristic parameters include average value and peak-to-peak value;

当配置参数对应的场景为切削过载场景时，特征参数包括平均值、均方根、峰峰值；When the scene corresponding to the configuration parameters is a cutting overload scene, the characteristic parameters include average value, root mean square, and peak-to-peak value;

当配置参数对应的场景为异常换刀场景时，特征参数包括平均值；When the scene corresponding to the configuration parameters is an abnormal tool change scene, the characteristic parameters include the average value;

当配置参数对应的场景为重切削场景时，特征参数包括平均值、均方根、峰峰值；When the scene corresponding to the configuration parameters is a heavy cutting scene, the characteristic parameters include average value, root mean square, and peak-to-peak value;

当配置参数对应的场景为各伺服轴磨损时，特征参数包括域值；When the scenario corresponding to the configuration parameters is that each servo axis is worn out, the characteristic parameters include threshold values;

当配置参数对应的场景为重复加工监控场景时，特征参数包括平均值和均方根；When the scene corresponding to the configuration parameters is a repeated processing monitoring scene, the characteristic parameters include average value and root mean square;

当配置参数对应的场景为重点刀具监控场景时，特征参数同时包括平均值、均方根和峰峰值；When the scene corresponding to the configuration parameters is a key tool monitoring scene, the characteristic parameters include the average value, root mean square and peak-to-peak value at the same time;

当配置参数对应的场景为自适应控制场景时，特征参数包括平均值和均方根；When the scenario corresponding to the configuration parameters is an adaptive control scenario, the characteristic parameters include average value and root mean square;

当配置参数对应的场景为自定义场景时，特征参数根据自定义场景进行设定。When the scene corresponding to the configuration parameters is a custom scene, the feature parameters are set according to the custom scene.
根据权利要求1所述的机床机械部件动态保护方法，其中，所述特征参数的提取方式包括：The method for dynamic protection of machine tool mechanical parts according to claim 1, wherein the method of extracting the characteristic parameters comprises:

所述峰峰值的获取方式为根据第二振动数据的波形图，计算波形图中的波峰波谷值；The method of obtaining the peak-to-peak value is to calculate the peak-to-valley value in the waveform diagram according to the waveform diagram of the second vibration data;

所述平均值的计算方法为获取第二振动数据，将同一组X轴向数据、Y轴向数据、Z轴向数据按照向量和的计算方法进行计算，得到该组数据的向量和，并与相邻时间采集的两组三轴向数据的向量和进行平均数计算，得到所述平均值；The calculation method of the average value is to obtain the second vibration data, calculate the same group of X-axis data, Y-axis data, and Z-axis data according to the calculation method of vector sum, obtain the vector sum of this group of data, and compare with The vector sum of the two groups of three-axis data collected at adjacent times is calculated to obtain the average value;

所述均方根的计算方法为获取第二振动数据，对第二振动数据中，以时间为基准，向后连续选取设定数量的以连续3组为基本单元的三轴向数据，每连续3组按照X轴向数据、Y轴向数据、Z轴向数据分别进行均方根的计算，再获取设定数量的基本单元的均方根进行均值计算；The calculation method of the root mean square is to obtain the second vibration data, and for the second vibration data, taking time as the reference, continuously select a set number of three-axis data with three consecutive groups as the basic unit backwards, and each continuous The three groups perform root mean square calculations according to the X-axis data, Y-axis data, and Z-axis data, and then obtain the root mean square of the set number of basic units for mean calculation;

所述域值的计算方法为获取第二振动数据的波动范围值。The calculation method of the threshold value is to obtain the fluctuation range value of the second vibration data.
根据权利要求1所述的机床机械部件动态保护方法，其中，所述机床机械部件动态保护方法中，根据所述对比结果，确定报警方式，和/或对机床进行调整的步骤包括：The method for dynamically protecting mechanical parts of a machine tool according to claim 1, wherein, in the method for dynamically protecting mechanical parts of a machine tool, according to the comparison result, determining an alarm mode and/or adjusting the machine tool includes:

若所述对比结果小于所述预设阈值，则机床维持所述机床操作状态；If the comparison result is less than the preset threshold, the machine tool maintains the machine tool operating state;

若所述对比结果大于或等于所述预设阈值，所述报警反馈模块根据所述场景检测参数及所述第二振动数据确定故障信息，并发出报警信息，对机床进行调整。If the comparison result is greater than or equal to the preset threshold, the alarm feedback module determines fault information according to the scene detection parameters and the second vibration data, and sends out an alarm message to adjust the machine tool.
一种数控机床设备，包括主机、三轴加速度传感器、数控装置和驱动装置；A numerically controlled machine tool, comprising a host, a three-axis acceleration sensor, a numerically controlled device, and a driving device;

所述三轴加速度传感器设置于所述主机上，三轴加速度传感器设置为监测所述主机的运行状态；The three-axis acceleration sensor is set on the host, and the three-axis acceleration sensor is set to monitor the running state of the host;

所述驱动装置设置为驱动所述主机；The driving device is configured to drive the host;

所述数控装置设置为与所述主机、所述三轴加速度传感器、所述驱动装置分别电连接；The numerical control device is configured to be electrically connected to the host computer, the three-axis acceleration sensor, and the driving device, respectively;

其中，所述数控装置包括：数据采集模块，场景检测模块，数据处理模块，报警反馈模块，设备管理模块，供电电源，通讯模块以及Flash芯片；Wherein, described numerical control device comprises: data acquisition module, scene detection module, data processing module, alarm feedback module, equipment management module, power supply, communication module and Flash chip;

所述数据采集模块设置为获取三轴加速度传感器的反馈数据；The data acquisition module is configured to obtain the feedback data of the three-axis acceleration sensor;

所述场景检测模块设置为检测或提供机床的操作状态；The scene detection module is configured to detect or provide the operating state of the machine tool;

所述数据处理模块设置为根据机床的操作状态，调用配置参数，对三轴加速度传感器的反馈数据进行数据预处理；The data processing module is configured to call configuration parameters according to the operating state of the machine tool, and perform data preprocessing on the feedback data of the three-axis acceleration sensor;

所述报警反馈模块设置为对数据处理模块的预处理后的数据进行提取与计算，并分析计算结果，对应地进行报警和/或对机床进行调整；The alarm feedback module is configured to extract and calculate the preprocessed data of the data processing module, analyze the calculation results, and correspondingly alarm and/or adjust the machine tool;

所述设备管理模块设置为预设主机运行参数和人机交互；The device management module is set to preset host operating parameters and human-computer interaction;

所述供电电源设置为给所述数控装置供电；The power supply is configured to supply power to the numerical control device;

所述通讯模块设置为传递数据及信号；The communication module is configured to transmit data and signals;

所述Flash芯片设置为存储机床运行数据。The Flash chip is set to store machine tool operation data.
根据权利要求8所述的数控机床设备，其中，所述报警反馈模块被设置为根据分析计算结果采取如下动作：提示报警，急停报警，断电，NC暂停，伺服轴锁定，进给保持，或，独立双回路急停触点。The CNC machine tool equipment according to claim 8, wherein the alarm feedback module is configured to take the following actions according to the analysis and calculation results: prompt alarm, emergency stop alarm, power failure, NC pause, servo axis lock, feed hold, Or, independent dual circuit emergency stop contacts.
根据权利要求8所述的数控机床设备，其中，所述通讯模块包括IO模块、以太网、总线协议、RS232、RS485、Ether Cat、Profinet、Profibus或RS422。The numerically controlled machine tool equipment according to claim 8, wherein the communication module includes an IO module, Ethernet, bus protocol, RS232, RS485, Ether Cat, Profinet, Profibus or RS422.