An adaptive control system for industrial equipment

Abstract

The invention discloses an adaptive control system for industrial equipment, relates to the technical field of industrial equipment control, and comprises a data acquisition module, a data processing module, a rate analysis module, a matching module, and a control module. The invention solves the technical problem that when the extension length of a milling cutter is long, if the cutting rate of the milling cutter is high, the deflection and vibration of the milling cutter when cutting the outer contour of a workpiece are very likely to be large, and thus the workpiece processing inaccuracy is very likely to be caused. The actual cutting rate of the milling cutter is adjusted accordingly according to the cutting rate corresponding to the extension length range of the milling cutter, so that the deflection value of the milling cutter when cutting at different extension lengths is minimized and the vibration frequency is reasonable as much as possible, so that the inaccuracy of workpiece processing caused by the large deflection and vibration frequency of the milling cutter when cutting is reduced, and the processing accuracy of the milling cutter on the workpiece is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial equipment control, and in particular to an industrial equipment adaptive control system. Background Art

[0002] Industrial equipment refers to industrial production equipment and various machine tools, such as lathes, milling machines, grinders, planers and other machines; milling machines mainly refer to machine tools that use milling cutters to process various surfaces of workpieces. Usually, the main movement is the rotation of the milling cutter. Milling machines are machine tools that use milling cutters to mill workpieces. In addition to milling planes, grooves, gear teeth, threads and spline shafts, milling machines can also process more complex surfaces and workpiece outer contours. They are more efficient than planers and are widely used in machinery manufacturing and repair departments.

[0003] However, in the process of cutting the outer contour of a workpiece such as a mold, when part of the cutting point is low, it is necessary to lengthen the extension length of the milling cutter. When the extension length of the milling cutter is long, if the cutting rate of the milling cutter is high, it is very easy for the milling cutter to have large deflection and vibration during the cutting process of the outer contour of the workpiece, which can easily lead to inaccurate workpiece processing, affect the processing effect of the workpiece, and even cause damage to the tool. Therefore, an adaptive control system for industrial equipment is proposed. Summary of the invention

[0004] The purpose of the present invention is to provide an adaptive control system for industrial equipment to solve the technical problem that when the extension length of the milling cutter is long, if the cutting rate of the milling cutter is high, the deflection and vibration of the milling cutter when cutting the outer contour of the workpiece will be large, which will easily lead to inaccurate workpiece processing.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] An industrial equipment adaptive control system, comprising:

[0007] A data acquisition module is used to acquire a plurality of actual movement trajectories corresponding to the process of milling the contour of the same workpiece with the milling cutter at n different extension lengths, and transmit the actual movement trajectory and the theoretical movement trajectory to the data processing module, and transmit the vibration frequency to the vibration analysis module;

[0008] A data processing module is used to analyze and process a plurality of actual movement trajectories corresponding to the milling cutter at different extension lengths and a theoretical movement trajectory of the milling cutter, thereby obtaining a reference velocity of the milling cutter at different extension lengths and sending it to a velocity analysis module;

[0009] A vibration analysis module is used to obtain and analyze the vibration frequency of the milling cutter at n different extension lengths during the machining process, and then obtain the vibration parameter values ​​of the milling cutter at different extension lengths and their corresponding standard rates, and send them to the rate analysis module;

[0010] The rate analysis module is used to analyze and calculate the reference rate and standard rate corresponding to the milling cutter under n different target extension lengths, and then obtain the adjustment parameter value of the milling cutter cutting rate corresponding to the milling cutter under different target extension lengths, and transmit it to the matching module:

[0011] A matching module is used to obtain the length values ​​corresponding to the milling cutter at n different extension lengths, and divide the length range according to the corresponding length values ​​obtained, and at the same time, the adjustment parameter values ​​of the milling cutter cutting rate are matched one by one with each length range and matched to generate a rate matching table, and at the same time, the rate matching table is transmitted to the control module;

[0012] The control module is used to monitor the actual extension length of the milling cutter and determine the length range corresponding to the actual extension length of the milling cutter, and then adjust the actual cutting speed of the milling cutter accordingly according to the adjustment parameter value corresponding to the length range in the speed matching table.

[0013] As a further solution of the present invention: the specific method of calculating the reference rate is:

[0014] S1: Selecting a protrusion length from n different protrusion lengths of the milling cutter as the target protrusion length of the milling cutter;

[0015] S2: Obtain the theoretical trajectory of the milling cutter at the target extension length and its trajectory center point, obtain the maximum distance between multiple actual movement trajectories corresponding to the target extension length of the milling cutter and the center point of the theoretical trajectory and mark them as deflection values ​​P1, P2, ..., Pj in sequence, where j refers to the number of actual movement trajectories corresponding to the target extension length of the milling cutter, j = 1, 2, ..., d1;

[0016] S3: Calculate the average value of the deflection values ​​Pj of multiple actual moving trajectories corresponding to the milling cutter and mark it as Pa, and extract all Pj satisfying |Pj-Pa|≤Q1 from the multiple Pj, where Q1 is a preset value;

[0017] S4: Compare the values ​​of Pj that satisfy |Pj-Pa|≤Q1, select the one with the smallest Pj value and mark it as P min , extract P min The cutting rate of the milling cutter corresponding to the corresponding actual moving trajectory is marked as a reference rate B1, and the reference rate B1 is transmitted to the control module;

[0018] S5: Repeat the above steps S1 - S4 to obtain the reference speeds of the milling cutter at n different extended lengths respectively, and mark them as B11, B12, …, B1n in sequence.

[0019] As a further solution of the present invention: The calculation method of the vibration parameter value of the milling cutter at different extended lengths is as follows:

[0020] S01: Select one extended length from the n different extended lengths of the milling cutter as the target extended length of the milling cutter;

[0021] S02: Obtain the maximum vibration frequency when the milling cutter performs contour milling on v identical workpieces at the target extended length, and mark them as Z1, Z2, …, Zv in sequence, where v = 1, 2, …, d2;

[0022] S03: Extract the maximum value and the minimum value in Zv, and mark them as Z max and the value Z min , and calculate the range value J corresponding to v Zv through the formula Z max -Z min = J;

[0023] When J ≤ Q2, then take Zv as the standard vibration frequency D1 corresponding to the milling cutter at the target extended length; when J > Q2, then delete Zv in sequence from large to small according to the corresponding values of Zv, and record the number x of the deleted Zv at the same time, until J ≤ Q2 is satisfied; if x < Q3, then calculate the mean value Zv of the remaining Zv after deletion, and take it as the standard vibration frequency D1 corresponding to the milling cutter at the target extended length; if x ≥ Q3, then calculate the mean value of the maximum value and the minimum value of the remaining Zv, and take it as the standard vibration frequency D1 corresponding to the milling cutter at the target extended length;

[0024] S04: Obtain the mean value of the cutting speed of the milling cutter corresponding to the standard vibration frequency D1 of the target extended length, and mark it as the standard speed B2 and send it to the control module;

[0025] S05: Repeat the above steps S01 - S04 to obtain the standard speeds B2 corresponding to the milling cutter at n different target extended lengths, and mark them as B21, B22, …, B2n in sequence.

[0026] As a further solution of the present invention: The specific method for calculating the parameter adjustment value is as follows:

[0027] Obtain the parameter adjustment value Ln corresponding to the cutting speed of the milling cutter at n different extended lengths through the formula A1×B1n + A2×B2n = Ln, where A1 and A2 are both preset proportional coefficients.

[0028] As a further solution of the present invention: a matching module is used to obtain the length values ​​corresponding to the milling cutter at n different extension lengths, and mark them as W1, W2, ..., Wn in sequence, and divide the length range according to the corresponding length value Wn obtained, and the specific method of length range division is: (0, W1], (W1, W2], (W2, W3], ..., (Wn-1, Wn]; the n adjustment parameter values ​​Ln are respectively matched one by one with each length range and matched to generate a rate matching table, and the transmission rate matching table is sent to the control module.

[0029] Beneficial effects of the present invention:

[0030] The present invention obtains the length values ​​corresponding to the milling cutter at different extended lengths and divides them into corresponding length intervals, and at the same time, the adjustment parameter values ​​corresponding to the cutting rate of the milling cutter at different extended lengths are respectively matched one by one with each length range and matched to generate a rate matching table. When the extended length of the milling cutter is within a certain length range, the cutting rate of the milling cutter can be adjusted accordingly according to the cutting rate corresponding to the length range, so that the deflection value of the milling cutter when performing cutting work at different extended lengths is as small as possible and the vibration frequency is reasonable, so as to avoid the inaccuracy of workpiece processing due to the large deflection and vibration frequency of the milling cutter when performing cutting work, thereby improving the processing accuracy of the milling cutter on the workpiece, further ensuring the processing effect of the workpiece, and avoiding the damage of the tool as much as possible. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The present invention will be further described below in conjunction with the accompanying drawings.

[0032] Figure 1 It is a schematic diagram of the framework structure of an industrial equipment adaptive control system of the present invention. DETAILED DESCRIPTION

[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] See also Figure 1 As shown, the present invention is an industrial equipment adaptive control system, comprising:

[0035] A data acquisition module is used to acquire a plurality of actual movement trajectories corresponding to the milling cutter being at n different extension lengths during the milling process of the same workpiece, and a theoretical movement trajectory of the milling cutter at n different extension lengths, and transmit both the actual movement trajectory and the theoretical movement trajectory corresponding to the milling cutter being at n different extension lengths to the data processing module, and simultaneously acquire the vibration frequency of the milling cutter at n different extension lengths during the processing, and transmit it to the vibration analysis module, n=1, 2, ..., d2;

[0036] It should be noted that the different extension lengths of the milling cutter are randomly selected, and the difference between every two adjacent extension lengths of n different extension lengths can be the same or different. The relevant management personnel can adjust the value according to the actual situation;

[0037] The data processing module is used to analyze and process multiple actual movement trajectories corresponding to the milling cutter at different extension lengths and the theoretical movement trajectory of the milling cutter, thereby obtaining the reference speed of the milling cutter at different extension lengths and sending it to the speed analysis module. The specific method for calculating the reference speed is:

[0038] S1: Selecting a protrusion length from n different protrusion lengths of the milling cutter as the target protrusion length of the milling cutter;

[0039] S2: Obtain the theoretical trajectory of the milling cutter at the target extension length and its trajectory center point, obtain the maximum distance between multiple actual movement trajectories corresponding to the target extension length of the milling cutter and the center point of the theoretical trajectory and mark them as deflection values ​​P1, P2, ..., Pj in sequence, where j refers to the number of actual movement trajectories corresponding to the target extension length of the milling cutter, j = 1, 2, ..., d1;

[0040] S3: Calculate the average value of the deflection values ​​Pj of multiple actual moving trajectories corresponding to the milling cutter and mark it as Pa, and extract all Pj satisfying |Pj-Pa|≤Q1 from the multiple Pj, where Q1 is a preset value, which can be adjusted by relevant management personnel according to actual needs;

[0041] S4: Compare the values ​​of Pj that satisfy |Pj-Pa|≤Q1, select the one with the smallest Pj value and mark it as P min , extract P min The cutting rate of the milling cutter corresponding to the corresponding actual moving trajectory is marked as a reference rate B1, and the reference rate B1 is transmitted to the control module;

[0042] S5: Repeat the above steps S1 - S4 to obtain the reference rates of the milling cutter at n different extended lengths respectively, and mark them as B11, B12, …, B1n in sequence;

[0043] A vibration analysis module, configured to obtain and analyze the vibration frequencies of the milling cutter at n different extended lengths during the machining process, so as to obtain the vibration parameter values and their corresponding standard rates of the milling cutter at different extended lengths. The calculation method of the vibration parameter values of the milling cutter at different extended lengths is as follows:

[0044] S01: Select one extended length from the n different extended lengths of the milling cutter as the target extended length of the milling cutter;

[0045] S02: Obtain the maximum vibration frequency of the milling cutter when milling the contour of v identical workpieces at the target extended length, and mark them as Z1, Z2, …, Zv in sequence, where v = 1, 2, …, d2;

[0046] S03: Extract the maximum value and the minimum value from Zv, and mark them as Z max and the sum value Z min , and calculate the range value J of the v Zv values through the formula Z max -Z min = J. The larger the range value J, the greater the dispersion degree of the v Zv values, and vice versa;

[0047] When J ≤ Q2, then take as the standard vibration frequency D1 corresponding to the milling cutter at the target extended length; when J > Q2, then delete Zv in descending order according to the corresponding values of Zv, and record the number x of the deleted Zv at the same time, until J ≤ Q2 is satisfied; if x < Q3, calculate the mean value of the remaining Zv after deletion and take it as the standard vibration frequency D1 corresponding to the milling cutter at the target extended length; if x ≥ Q3, calculate the mean value of the maximum value and the minimum value of the remaining Zv, and take it as the standard vibration frequency D1 corresponding to the milling cutter at the target extended length;

[0048] S04: Obtain the mean value of the cutting rate of the milling cutter corresponding to the standard vibration frequency D1 of the target extended length, and mark it as the standard rate B2 and send it to the control module;

[0049] S05: Repeat the above steps S01 - S04 to obtain the standard rates B2 corresponding to the milling cutter at n different target extended lengths, and mark them as B21, B22, …, B2n in sequence;

[0050] The rate analysis module is used to analyze and calculate the reference rate B1n and the standard rate B2n corresponding to the milling cutter under n different target extension lengths, and then obtain the corresponding adjustment parameter values ​​of the milling cutter under different target extension lengths, and transmit them to the matching module. The specific method of calculating the adjustment parameter value is:

[0051] The adjustment parameter value Ln corresponding to the milling cutter cutting rate when the milling cutter is at n different extension lengths is obtained through the formula A1×B1n+A2×B2n=Ln. Here, A1 and A2 are both preset proportional coefficients, and relevant staff can adjust them according to actual conditions;

[0052] The matching module is used to obtain the length values ​​corresponding to the milling cutter at n different extension lengths, and mark them as W1, W2, ..., Wn in sequence, and divide the length range according to the corresponding length value Wn obtained, and the specific method of dividing the length range is: (0, W1], (W1, W2], (W2, W3], ..., (Wn-1, Wn]; the n adjustment parameter values ​​Ln are respectively matched with each length range one by one and matched to generate a rate matching table, and the transmission rate matching table is sent to the control module;

[0053] For example, for example, the length values ​​W1, W2, ..., Wn corresponding to the milling cutter at n different extension lengths are 5, 8, 12, ..., 15, 18 respectively. The specific method of dividing the length range according to the corresponding length value Wn obtained is: (0, 5], (5, 8], (8, 12], ..., (15, 18], and the n adjustment parameter values ​​Ln are respectively matched with each length range one by one and matched as follows: the adjustment parameter value L1 corresponding to 5 in the length range (0, 5] is matched with the length range (0, 5], and then the adjustment parameter value L2 corresponding to 8 in the length range (5, 8] is matched with the length range (5, 8], and so on, the adjustment parameter value Ln corresponding to Wn in the length range (Wn-1, Wn] is matched with the length range (Wn-1, Wn];

[0054] The milling cutter vibration data is obtained by fixing the accelerometer on the milling cutter to ensure that it is kept at a certain distance from the milling cutter, installing the milling cutter on the milling machine, starting the milling machine to allow the milling cutter to rotate and vibrate, using the accelerometer to measure the vibration magnitude of the milling cutter during the rotation process, and recording the vibration frequency of the milling cutter;

[0055] The control module is used to monitor the actual extension length of the milling cutter and determine the length range corresponding to the actual extension length of the milling cutter, and then adjust the actual cutting rate of the milling cutter accordingly according to the adjustment parameter value corresponding to the length range in the rate matching table, so that when the extension length of the milling cutter is within a certain length range, the possibility of the milling cutter vibrating at a high frequency due to excessive cutting rate during cutting work is minimized, thereby reducing the possibility of reducing the machining accuracy of the milling cutter and affecting the machining effect of the workpiece.

[0056] The working principle of the present invention is as follows: first, by analyzing and calculating the deflection value of the milling cutter at different extension lengths, the cutting rate corresponding to the minimum deflection value of the milling cutter at different extension lengths is obtained, which is used as the reference rate of the milling cutter at different extension lengths; then, by analyzing and processing the vibration frequency of the milling cutter at different extension lengths, the standard vibration frequency of the milling cutter at different extension lengths and the standard rate corresponding to the standard vibration frequency are obtained; then, the adjustment parameter value corresponding to the milling cutter cutting rate at different extension lengths is calculated by the reference rate and the standard rate of the milling cutter at different extension lengths; finally, the length values ​​corresponding to the milling cutter at different extension lengths are obtained and divided into corresponding length intervals; at the same time, the adjustment parameter values ​​corresponding to the milling cutter cutting rate at different extension lengths are respectively matched one by one with each length range and matched to generate a rate matching table; when the extension length of the milling cutter is within a certain length range, the cutting rate of the milling cutter can be adjusted accordingly according to the cutting rate corresponding to the length range, so that the deflection value of the milling cutter when performing cutting work at different extension lengths is as small as possible and the vibration frequency is reasonable, thereby improving the processing accuracy of the milling cutter on the workpiece.

[0057] The above formulas are all dimensionless and numerical calculations. The formula is a formula for the most recent real situation obtained by collecting a large amount of data and performing software simulation. The preset parameters and thresholds in the formula are set by technicians in this field according to actual conditions.

[0058] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. An industrial equipment adaptive control system, characterized in that: include: A data acquisition module is used to acquire a plurality of actual movement trajectories corresponding to the process of milling the contour of the same workpiece with the milling cutter at n different extension lengths, and transmit the actual movement trajectory and the theoretical movement trajectory to the data processing module, and transmit the vibration frequency to the vibration analysis module; A data processing module is used to analyze and process a plurality of actual movement trajectories corresponding to the milling cutter at different extension lengths and a theoretical movement trajectory of the milling cutter, thereby obtaining a reference velocity of the milling cutter at different extension lengths and sending it to a velocity analysis module; A vibration analysis module is used to obtain and analyze the vibration frequency of the milling cutter at n different extension lengths during the machining process, and then obtain the vibration parameter values ​​of the milling cutter at different extension lengths and their corresponding standard rates, and send them to the rate analysis module; The rate analysis module is used to analyze and calculate the reference rate and standard rate corresponding to the milling cutter under n different target extension lengths, and then obtain the adjustment parameter value of the milling cutter cutting rate corresponding to the milling cutter under different target extension lengths, and transmit it to the matching module: A matching module is used to obtain the length values ​​corresponding to the milling cutter at n different extension lengths, and divide the length range according to the corresponding length values ​​obtained, and at the same time, the adjustment parameter values ​​of the milling cutter cutting rate are matched one by one with each length range and matched to generate a rate matching table, and at the same time, the rate matching table is transmitted to the control module; The control module is used to monitor the actual extension length of the milling cutter and determine the length range corresponding to the actual extension length of the milling cutter, and then adjust the actual cutting speed of the milling cutter accordingly according to the adjustment parameter value corresponding to the length range in the speed matching table.

2. An industrial equipment adaptive control system according to claim 1, characterized in that: The specific method for calculating the reference rate is: S1: Selecting a protrusion length from n different protrusion lengths of the milling cutter as the target protrusion length of the milling cutter; S2: Obtain the theoretical trajectory of the milling cutter at the target extension length and its trajectory center point, obtain the maximum distance between multiple actual movement trajectories corresponding to the target extension length of the milling cutter and the center point of the theoretical trajectory and mark them as deflection values ​​P1, P2, ..., Pj in sequence, where j refers to the number of actual movement trajectories corresponding to the target extension length of the milling cutter, j = 1, 2, ..., d1; S3: Calculate the average value of the deflection values ​​Pj of multiple actual moving trajectories corresponding to the milling cutter and mark it as Pa, and extract all Pj satisfying |Pj-Pa|≤Q1 from the multiple Pj, where Q1 is a preset value; S4: Compare the values ​​of Pj that satisfy |Pj-Pa|≤Q1, select the one with the smallest Pj value and mark it as P min , extract P min The cutting rate of the milling cutter corresponding to the corresponding actual moving trajectory is marked as a reference rate B1, and the reference rate B1 is transmitted to the control module; S5: Repeat the above steps S1-S4 to obtain the reference rates of the milling cutter at n different extension lengths respectively, and mark them as B11, B12, ..., B1n in sequence.

3. An industrial equipment adaptive control system according to claim 2, characterized in that: The calculation method of the vibration parameter value of the milling cutter at different extension lengths is: S01: Selecting one extension length from n different extension lengths of the milling cutter as a target extension length of the milling cutter; S02: Obtain the maximum vibration frequency of the milling cutter when milling the contour of v identical workpieces at the target protrusion length, and label them as Z1, Z2, …, Zv in sequence, where v = 1, 2, …, d2; S03: Extract the maximum and minimum values ​​in Zv and mark them as Z respectively max Sum value Z min , through the formula Z max -Z min =J, calculate the extreme difference value J corresponding to v Zv; When J ≤ Q2, then take Zv as the standard vibration frequency D1 corresponding to the milling cutter at the target protrusion length; when J > Q2, then delete Zv in descending order according to the corresponding values of Zv, and record the number x of deleted Zv at the same time, until J ≤ Q2 is satisfied; if x < Q3, then calculate the mean value Zv of the remaining Zv after deletion, and take it as the standard vibration frequency D1 corresponding to the milling cutter at the target protrusion length; if x ≥ Q3, then calculate the mean value of the maximum and minimum values of the remaining Zv, and take it as the standard vibration frequency D1 corresponding to the milling cutter at the target protrusion length; S04: Obtain the mean value of the cutting rate of the milling cutter corresponding to the standard vibration frequency D1 of the target protrusion length, and label it as the standard rate B2 and send it to the control module; S05: Repeat the above steps S01 - S04 to obtain the standard rates B2 corresponding to the milling cutter at n different target protrusion lengths, and label them as B21, B22, …, B2n in sequence.

4. An industrial equipment adaptive control system according to claim 3, characterized in that: The specific method for calculating the tuning parameter value is: Obtain the tuning parameter value Ln corresponding to the cutting rate of the milling cutter when the milling cutter is at n different protrusion lengths through the formula A1×B1n + A2×B2n = Ln, where A1 and A2 are both preset proportionality coefficients.

5. The industrial equipment adaptive control system according to claim 1, characterized in that: The matching module is used to obtain the length values corresponding to the milling cutter at n different protrusion lengths, and label them as W1, W2, …, Wn in sequence, and divide the length range according to the obtained corresponding length values Wn. The specific method for dividing the length range is: (0, W1], (W1, W2], (W2, W3], …, (Wn - 1, Wn]; Correspond and match the n tuning parameter values Ln with each length range one by one to generate a rate matching table, and send the transmission rate matching table to the control module.

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