Cutter replacement early warning method, cutter replacement early warning device and numerical control machining system

Abstract

The invention relates to a tool replacement early warning method, a tool replacement early warning device and a numerical control machining system. The tool replacement early warning method is applied to the tool replacement early warning device. The cutter comprises a functional layer and a transition layer; the tool replacement early warning device stores a normal operation interval of mechanical wave data when the tool normally machines a workpiece; the method comprises the following steps: acquiring to-be-detected mechanical wave data generated by an operation tool in the process of processing an operation workpiece at a set frequency, and judging whether the to-be-detected mechanical wave data exceeds the normal operation interval or not; and when the to-be-detected mechanical wave data exceed the normal operation interval, outputting an early warning signal. According to the invention, precise monitoring of wear in the tool operation process can be realized, and timely early warning can be realized.

Description

Technical Field

[0001] The present application relates to the technical field of numerical control machining, and more specifically, to a tool replacement warning method and a tool replacement warning device and a numerical control machining system. Background Art

[0002] A CNC machine tool is an automated machine tool equipped with a program control system that can automatically control the tool to perform processing operations.

[0003] The tools used in CNC machine tools generally have a multi-layer structure including a base layer, a transition layer, and a functional layer. The base layer is used as the base structure of the tool. The transition layer is set between the base layer and the functional layer to achieve the connection between the base layer and the functional layer. The functional layer is used for processing. Since the functions of each layer of the tool are different, the materials and properties of the tool are also quite different.

[0004] During the machining process of CNC machine tools, the tool will wear due to the operation of the machining operation. At this time, it is particularly important to monitor the wear of the tool. If the functional layer of the tool is worn, the operating layer will be converted from the functional layer to the transition layer. Due to the performance difference between the transition layer and the functional layer, it will be difficult to process the workpiece normally using the transition layer, affecting the product yield. If the tool is replaced some time in advance based on experience before the functional layer is completely damaged based on the previous wear time, the utilization rate of the tool will be reduced and the operating cost will be increased. Summary of the invention

[0005] The technical problem to be solved by the present application is that, in view of the above-mentioned defects of the prior art, a tool replacement warning method is provided, which is applied to a tool replacement warning device; the tool comprises a functional layer and a transition layer; the tool replacement warning device stores a normal operating range of mechanical wave data when the tool normally processes a workpiece; the tool replacement warning method comprises the steps of:

[0006] S1: collecting the mechanical wave data to be measured generated by the working tool during the processing of the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the normal working range;

[0007] S2: When the mechanical wave data to be measured exceeds the normal operation range, output a warning signal.

[0008] In some embodiments, the tool replacement warning device stores a data model, and the data model includes materials of the tools of various materials and their corresponding normal working ranges;

[0009] The step S1 comprises:

[0010] S11, obtaining the material of the working tool, and selecting the corresponding normal working range in the data model according to the material of the working tool;

[0011] S12, collecting the mechanical wave data to be measured generated by the working tool during the processing of the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the corresponding normal working range.

[0012] In some embodiments, step S1 includes:

[0013] S11, obtaining the material of the working tool, and judging whether the material of the working tool belongs to the material in the data model according to the material of the working tool;

[0014] S121, if the material belongs to the data model, then according to the material of the working tool, select the corresponding normal working range in the data model;

[0015] S122, collecting the mechanical wave data to be measured generated by the working tool during the process of machining the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the corresponding normal working range;

[0016] S131, if the material does not belong to the data model, obtaining mechanical wave data generated by the working tool when processing the working workpiece;

[0017] S132, obtaining the normal operation range of the operation tool according to the mechanical wave data;

[0018] S133, updating the material and the corresponding normal operation range into the data model.

[0019] In some embodiments, the data model includes materials of the tool of multiple materials, materials of the workpiece of multiple materials, and normal working ranges corresponding to the material combinations thereof;

[0020] The step S1 comprises:

[0021] S11, obtaining the material of the working tool and the material of the working workpiece, and selecting the corresponding normal working range in the data model according to the combination of the material of the working tool and the material of the working workpiece;

[0022] S12, collecting the mechanical wave data to be measured generated by the working tool during the process of machining the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the corresponding normal working range.

[0023] In some embodiments, the normal operation interval includes a frequency interval and an amplitude interval; the mechanical wave data to be measured includes amplitude data to be measured and frequency data to be measured; the tool replacement warning device stores an alarm threshold;

[0024] The step S1 comprises:

[0025] S11, collecting the frequency data to be measured and the amplitude data to be measured generated by the working tool in the process of machining the working workpiece at a set frequency, and calculating the proportion of the frequency data to be measured and the amplitude data to be measured exceeding the frequency interval and the amplitude interval within a collection period;

[0026] S12, determining whether the quantity ratio is greater than an alarm threshold;

[0027] The step S2 comprises:

[0028] When the quantity ratio is greater than the alarm threshold, an early warning signal is output.

[0029] In some embodiments, step S1 includes:

[0030] After the working tool processes the working workpiece for a set time, the mechanical wave data to be measured generated by the working tool in the process of processing the working workpiece is collected at a set frequency, and it is determined whether the mechanical wave data to be measured exceeds the normal working range.

[0031] Construct a tool replacement early warning device, comprising:

[0032] A state detection mechanism is used to collect the mechanical wave data to be measured generated by the working tool during the processing of the working workpiece at a set frequency;

[0033] The main control mechanism stores the normal operating range and is electrically connected to the status detection mechanism; it is used to receive the mechanical wave data to be tested and determine whether the mechanical wave data to be tested exceeds the normal operating range, so as to output a warning signal when the mechanical wave data to be tested exceeds the normal operating range.

[0034] In some embodiments, the main control mechanism includes a collection module and a receiving module;

[0035] The acquisition module is electrically connected to the state detection mechanism, and is used to receive the mechanical wave data to be measured, convert it into a wireless signal, and transmit it wirelessly to the receiving module;

[0036] The receiving module stores the normal operating range and is used to receive the wireless signal and determine whether the corresponding mechanical wave data to be tested exceeds the normal operating range according to the wireless signal, so as to output a warning signal when the mechanical wave data exceeds the normal operating range.

[0037] In some embodiments, the state detection mechanism is further used to obtain mechanical wave data of the test tool when processing a test workpiece; and the main control mechanism is further used to obtain and store the normal operation interval according to the mechanical wave data.

[0038] A CNC machining system is constructed, comprising a CNC machining device and a tool replacement warning device as described in any of the aforementioned embodiments; the CNC machining device comprises a machine tool, a fixture and a tool; the fixture is arranged on the machine tool, and the tool is detachably arranged on the fixture; at least part of the tool replacement warning device is arranged on the machine tool, and / or the fixture, and / or the tool.

[0039] In some embodiments, at least a portion of the tool replacement warning device is embedded or buried in the fixture.

[0040] In some embodiments, the number of tool replacement warning devices is at least two, and they are evenly spaced along the circumference of the fixture.

[0041] In some embodiments, an assembly groove is formed on the fixture; the tool replacement warning device also includes a shell embedded in the assembly groove; at least part of the main control mechanism and the status detection mechanism are respectively arranged in the shell, and the status detection mechanism is arranged on the side of the main control mechanism close to the groove wall of the assembly groove, and is arranged adjacent to the groove wall of the assembly groove through the shell.

[0042] The implementation of the technical solution constructed in this application has at least the following beneficial effects:

[0043] This application is configured to detect mechanical waves, and can utilize various data reflected by mechanical waves to effectively improve the accuracy of monitoring. This application utilizes the differences in material properties between the various layers of the tool, combined with the differences in the mechanical waves corresponding to them, to achieve accurate judgment of the working layer in which the tool is operating. This can avoid the situation where the tool is not replaced in time and the transition layer is used to process the workpiece, thereby avoiding a reduction in the product yield rate. At the same time, it can also maximize the utilization rate of the tool, avoid replacing the tool when its working layer is still a functional layer, and control operating costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The present application will be further described below with reference to the accompanying drawings and embodiments, in which:

[0045] Figure 1 is a flow chart of a tool replacement warning method in one embodiment of the present application;

[0046] Figure 2 yes Figure 1 Step S1 shown is a flow chart of an embodiment;

[0047] Figure 3 yes Figure 1 The step S1 shown is a flow chart of another embodiment;

[0048] Figure 4 yes Figure 1 The step S1 shown is a flow chart of another embodiment;

[0049] Figure 5 is a flow chart of a tool replacement early warning method in another embodiment of the present application;

[0050] Figure 6 is a flow chart of a tool replacement early warning method in another embodiment of the present application;

[0051] Figure 7 is a module relationship diagram of a tool replacement warning device in an embodiment of the present application;

[0052] Figure 8 is a schematic cross-sectional structure diagram of a partial structure of a numerical control machining system in an embodiment of the present application;

[0053] Fig. 9 yes Figure 8 A schematic cross-sectional view of a detection structure in a tool replacement warning device;

[0054] Fig.10 It is a schematic diagram of the cross-sectional structure of the tool. DETAILED DESCRIPTION

[0055] In order to have a clearer understanding of the technical features, purposes and effects of the present application, the specific implementation methods of the present application are now described in detail with reference to the accompanying drawings. In the following description, many specific details are set forth to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without violating the connotation of the present application, so the present application is not limited by the specific embodiments disclosed below.

[0056] In the description of the present application, it should be understood that the terms "longitudinal", "lateral", "up", "down", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings or the orientations or positional relationships in which the products of the present application are usually placed when used. They are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0057] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of the features. In the description of this application, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0058] In this application, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0059] In the present application, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being "above" a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being "below" a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0060] The present application constructs a tool replacement warning method, which can be applied to a tool replacement warning device 10 to provide a replacement warning for a tool 30 operating in a numerical control machining device.

[0061] It should be understood that the CNC machining device can use the tool 30 to machine the workpiece. Fig.10As shown, the tool 30 may include a base layer 34, a transition layer 33 and a functional layer 32. The base layer 34 is located at the innermost side and serves as the base layer structure of the tool 30. The transition layer 33 is located between the functional layer 32 and the base layer 34 and is used to achieve the transition between the functional layer 32 and the base layer 34 so that the functional layer 32 can be firmly arranged thereon. The functional layer 32 is mainly used to process the workpiece.

[0062] During the processing, friction will be generated between the functional layer 32 and the workpiece, thereby causing wear on the functional layer 32. When the functional layer 32 is worn through, so that the transition layer 33 is exposed, continuing to use the same tool 30 for processing will cause friction between the transition layer 33 and the workpiece. In other words, the workpiece will be processed using the transition layer 33. Since the functions of the transition layer 33 and the functional layer 32 are different, the materials they are made of are also different, and the material properties of the two are also different. Therefore, processing the workpiece with the transition layer 33 may cause the workpiece to fail to meet the standards, and there is even a risk of damaging the workpiece or equipment.

[0063] The tool replacement warning device 10 may store a normal operation range of mechanical wave data generated by the tool 30 during normal operation.

[0064] like Figure 1 As shown, the tool replacement warning method may include:

[0065] Step S1, collecting the measured mechanical wave data generated by the working tool during the processing of the working workpiece at a set frequency, and determining whether the measured mechanical wave data exceeds the normal working range.

[0066] Step S2: When the mechanical wave data to be measured exceeds the normal operating range, an early warning signal is output.

[0067] It should be understood that during the machining test, as the test tool and the test workpiece wear each other, the collected data will gradually change from the mechanical wave data generated during the operation of the functional layer 32 to the mechanical wave data generated during the operation of the transition layer 33. In the process of formally machining the workpiece, by collecting the mechanical wave data to be tested generated by the working tool and judging whether it exceeds the normal operating range, real-time monitoring of the working tool can be achieved. When the mechanical wave data to be tested exceeds the normal operating range, it can be understood that the working layer of the working tool has been converted from the functional layer 32 to the transition layer 33.

[0068] It should be understood that the normal operation range can be understood as the range of mechanical wave data generated by the friction between the functional layer 32 and the workpiece during the normal operation of the tool 30.

[0069] The tool replacement warning method provided in the present application can effectively improve the monitoring accuracy by detecting mechanical waves compared to monitoring by a single time or vibration frequency.

[0070] The present application utilizes the material property difference between the layers of the tool 30 and the difference of the corresponding mechanical waves to accurately determine the working layer of the tool 30. This can avoid the situation where the tool 30 is not replaced in time and the transition layer 33 is used to process the workpiece, thereby avoiding the reduction of the product yield rate. At the same time, it can also maximize the utilization rate of the tool 30, avoid replacing the tool 30 when its working layer is still the functional layer 32, and control the operating cost.

[0071] Read also Figure 7 The present application also constructs a tool replacement warning device 10, which can execute the tool replacement warning method.

[0072] Specifically, the tool replacement warning device 10 may include a main control mechanism 11 and a state detection mechanism 12. The state detection mechanism 12 may be electrically connected to the main control mechanism 11 and used to collect the mechanical wave data to be measured generated by the working tool during the processing of the working workpiece at a set frequency.

[0073] The main control mechanism 11 can store the normal operation interval corresponding to the mechanical wave data of the tool 30 in the normal operation state. It can also be used to receive the mechanical wave data to be tested collected by the state detection mechanism 12, and determine whether the mechanical wave data to be tested exceeds the normal operation interval. When the mechanical wave data to be tested exceeds the normal operation interval, it can output a warning signal.

[0074] In some embodiments, the state detection mechanism 12 can be implemented using an existing MEMS sensor (micro-electromechanical system sensor). It has the advantages of miniaturization, waterproofness, high stability, and strong anti-interference ability. In the process of collecting mechanical waves, the miniaturized structure allows it to be set on the fixture 20 that clamps the tool 30 to shorten the distance between it and the tool 30 and improve the accuracy of detection. At the same time, during the high-speed operation of the fixture 20, it can also perform stable operation through its own high stability and high anti-interference ability.

[0075] Specifically, the MEMS sensor can utilize its own micromechanical structure and a dedicated control circuit (ASIC) chip, wherein the dedicated control circuit chip can convert the external signal to be measured into signal changes such as capacitance, resistance or charge by affecting its micromechanical structure, and finally convert it into the form of an electrical signal to output the collected mechanical wave data and the mechanical wave data to be measured.

[0076] In some other optional embodiments, it can also be achieved by adopting other existing mechanical wave collection mechanisms such as high-frequency vibration sensors.

[0077] In some embodiments, the state detection mechanism 12 can also be used to obtain mechanical wave data of the test tool when processing the test workpiece. The main control mechanism 11 is also used to obtain and store the normal operation interval according to the mechanical wave data.

[0078] The working tool can be understood as a tool used in a normal machining operation of a workpiece to be machined by a numerical control machining device. The working workpiece can be understood as a workpiece to be machined in a normal machining operation of a numerical control machining device.

[0079] The test tool can be understood as the data of the material, size and other aspects of the test tool, which can include one or more data, and the working tool can belong to one of them, so as to improve the universality of the tool replacement warning device 10, and can warn and monitor tools of various materials. The data of the material, size and other aspects of the test workpiece can also include one or more data, and the working workpiece can also belong to one of them.

[0080] In some embodiments, when the test tool is made of multiple materials, the tool replacement warning device 10 may also store a data model, which may include the materials of multiple tools 30 and the normal working ranges corresponding to the materials.

[0081] like Figure 2 As shown, step S1 may also include:

[0082] Step S11, obtaining the material of the working tool, and selecting a normal working range corresponding to the material of the working tool in the data model.

[0083] Step S12: collecting the mechanical wave data to be measured generated by the working tool during the process of machining the workpiece at a set frequency, and determining whether the mechanical wave data exceeds the corresponding normal operation range.

[0084] Correspondingly, the state detection mechanism 12 of the tool replacement warning device 10 can also be used to sequentially obtain mechanical wave data of the test tools of various materials when processing the test workpiece.

[0085] The main control mechanism 11 can also be used to obtain and store the normal operation range corresponding to each test tool according to each mechanical wave data, and can also establish a data model according to the material of each test tool and the normal operation range corresponding to the material.

[0086] By testing the tools 30 of different materials and establishing a data model, the universality of the tool replacement warning device can be improved. Even if the CNC machining device replaces different working tools to process the workpiece, it can also use the tool replacement warning device 10 to monitor and warn the tool 30 through the tool replacement warning method.

[0087] like Figure 3 As shown, in some embodiments, step S1 may also include:

[0088] Step S11, obtaining the material of the working tool, and judging whether the material of the working tool belongs to the material in the data model according to the material of the working tool;

[0089] Step S121: If the material of the operating tool is one of the materials in the data model, then according to the material of the operating tool, a corresponding normal operating range is selected in the data model.

[0090] Step S122 , collecting the mechanical wave data to be measured generated by the working tool during the process of machining the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the corresponding normal operation range.

[0091] Step S131 : if the material of the working tool does not belong to any material in the data model, then obtaining the mechanical wave data generated by the working tool during the process of machining the working workpiece.

[0092] Step S132: Obtain the normal operation range of the operating tool according to the mechanical wave data.

[0093] Step S133: Update the material of the operating tool and its corresponding normal operating range into the data model.

[0094] The setting of steps S11 to S133 can continuously update the data model to increase the number of materials of the tool 30 that can be judged, and further improve the universality of the tool replacement warning device 10.

[0095] In some embodiments, when the test tool is made of multiple materials and the test workpiece is made of multiple materials, the data model can also include the materials of the tool 30 of multiple materials, the materials of the workpiece of multiple materials, and the normal working range corresponding to the combination of different tool 30 materials and different workpiece materials.

[0096] like Figure 4 As shown, step S1 may include:

[0097] Step S11 : obtaining the material of the working tool and the material of the working workpiece, and selecting a corresponding normal working range in the data model according to the material of the working tool and the material of the working workpiece.

[0098] Step S12: collecting the mechanical wave data to be measured generated by the working tool during the process of machining the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the corresponding normal working range.

[0099] Correspondingly, in some embodiments, the state detection mechanism 12 can also be used to sequentially obtain mechanical wave data of the test tools of various materials when processing the test workpieces of various materials. The main control mechanism 11 can also be used to obtain the normal operating range corresponding to the combination of each test tool and each test workpiece according to each mechanical wave data. It can also establish a data model according to the material of each test tool, the material of each test workpiece, and the normal working range corresponding to the combination of different test tool materials and different test workpiece materials.

[0100] It should be understood that during the machining process of the tool 30 on the workpiece, the friction surface materials of the two will respectively affect the mechanical waves generated by friction. By including the material of the workpiece in the detection range, the accuracy of the tool replacement warning method can be further improved.

[0101] Furthermore, step S1 may also include:

[0102] Step S11: Acquire the material of the working tool and the material of the working workpiece, and determine whether the material of the working tool and the material of the working workpiece belong to one of the material combinations corresponding to each normal working interval in the data model.

[0103] Step S121: If the material combination of the working tool and the working workpiece belongs to one of the material combinations corresponding to each normal working range in the data model, then select the corresponding normal working range in the data model according to the material combination.

[0104] Step S122 , collecting the mechanical wave data to be measured generated by the working tool during the process of machining the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the corresponding normal working range.

[0105] Step S131 : if the material combination of the working tool and the working workpiece does not belong to any of the material combinations corresponding to the normal working intervals in the data model, then obtain the mechanical wave data generated by the working tool during the processing of the working workpiece.

[0106] Step S132: Obtain the normal operation range of the operating tool according to the mechanical wave data generated.

[0107] Step S133: updating the normal operation range corresponding to the material of the operation tool, the material of the operation workpiece and the material combination thereof into the data model.

[0108] In some embodiments, the mechanical wave data may include frequency data and amplitude data. By simultaneously monitoring the frequency and amplitude of the mechanical wave, the accuracy of the early warning of the replacement of the tool 30 can be further improved. Correspondingly, the normal operation interval may include a frequency interval and an amplitude interval. The mechanical wave data to be measured may include amplitude data to be measured and frequency data to be measured.

[0109] like Figure 5 As shown, in some embodiments, step S1 may include:

[0110] Step S11, collecting the measured frequency data and the measured amplitude data of the measured mechanical wave generated by the working tool during the processing of the working workpiece at the set frequency, and calculating the proportion of the measured frequency data and the measured amplitude data exceeding the frequency interval and the amplitude interval within the collection period;

[0111] Step S12: determine whether the proportion of the quantity is greater than the alarm threshold.

[0112] The step S2 may include: when the proportion of the number is greater than the alarm threshold, outputting a warning signal.

[0113] Correspondingly, in some embodiments, the state detection mechanism 12 is also used to obtain frequency data and amplitude data of the test tool when processing the test workpiece. The main control mechanism 11 can also be used to store alarm thresholds, and obtain frequency intervals according to the frequency data, and obtain amplitude intervals according to the amplitude data.

[0114] It should be understood that since the functional layer 32 is mainly used to process the workpiece by friction with it, the transition layer 33 is mainly used to achieve transition between the functional layer 32 and the base layer 34. The functional difference between the two is reflected in the frequency and amplitude of the mechanical wave, that is, when the functional layer 32 of the tool 30 rubs against the workpiece and the transition layer 33 rubs against the workpiece, the frequency and amplitude of the mechanical wave will be reduced.

[0115] Therefore, the present application can monitor the wear condition of the tool 30 accurately according to the size of the data by monitoring the frequency data and amplitude data of the mechanical wave.

[0116] It should be understood that the collection period can be understood as the duration of each data collection, and the set frequency can be understood as the frequency of each collection.

[0117] In some embodiments, the acquisition period may be greater than or equal to 1 second and less than or equal to 2 seconds. Specifically, it may be 1.1 seconds, 1.2 seconds, 1.3 seconds, 1.4 seconds, 1.5 seconds, 1.6 seconds, 1.7 seconds, 1.8 seconds, 1.9 seconds, or any other value within the interval.

[0118] In some embodiments, the set frequency can be a set time for each interval, wherein the set time can be greater than or equal to 10 seconds and less than or equal to 120 seconds. Specifically, it can be 20 seconds, 30 seconds, 40 seconds, 50 seconds, 60 seconds, 70 seconds, 80 seconds, 90 seconds, 100 seconds, 110 seconds, or any other value within the interval.

[0119] It should be understood that calculating the percentage of the frequency data to be measured and the amplitude data to be measured that exceed the frequency interval and the amplitude interval can be understood as respectively calculating the percentage of the frequency data to be measured that exceed the frequency interval and the percentage of the amplitude data to be measured that exceed the amplitude interval. Correspondingly, the alarm threshold can include a frequency threshold and an amplitude threshold.

[0120] The proportion of the number of frequency data to be measured that exceeds the frequency interval is now defined as the frequency proportion, and the proportion of the number of amplitude data to be measured that exceeds the amplitude interval is defined as the amplitude proportion. Then, in step S2, when the number proportion is greater than the alarm threshold, an early warning signal is output. It can be understood that when the frequency proportion is greater than the frequency threshold, and / or the amplitude proportion is greater than the amplitude threshold, an early warning signal is output. No specific limitation is made here.

[0121] In some other optional embodiments, the alarm threshold may also be a single value. In this embodiment, in step S2, when the number ratio is greater than the alarm threshold, an early warning signal is output. It can be understood that when the frequency ratio is greater than the alarm threshold, and / or the amplitude ratio is greater than the alarm threshold, an early warning signal is output. It can also be understood that when the average of the frequency ratio and the amplitude ratio is greater than the alarm threshold, an early warning signal is output. No specific limitation is made here.

[0122] It should be understood that the alarm thresholds may be different for tools 30 of different materials and / or workpieces of different materials. Therefore, in some embodiments, the alarm threshold may be greater than or equal to 50% and less than or equal to 80%. For example, it may be 55%, 60%, 65%, 70%, 75%, or any other value within the range.

[0123] It should be understood that, for the data of mechanical waves, in addition to the influence of the material of the tool 30 and the workpiece, the environmental factors during the processing of the CNC machining device may also have a certain impact on it. Therefore, the determination of the alarm threshold can also be flexibly adjusted according to different environmental factors. In the process of collecting the frequency data to be measured and the amplitude data to be measured, the environmental factors can be kept consistent as much as possible with the environmental factors of the test tool when processing the test workpiece, so as to further improve the accuracy of monitoring and early warning.

[0124] In some embodiments, the mechanical wave may be a sound wave. Of course, in some other optional embodiments, the mechanical wave may also be a vibration wave.

[0125] like Fig.10 As shown, it should be understood that after the production of the tool 30 and before use, during transportation, storage, etc., the surface of the functional layer 32 will be oxidized to produce a protective layer 31. Of course, the protective layer 31 can also be specially attached to the surface of the functional layer 32 during the production process to protect the functional layer 32.

[0126] In the process of machining a workpiece using the tool 30, the protective layer 31 is worn first. Since the protective layer 31 is relatively thin, even if its material properties are different from those of the functional layer 32, it is difficult to affect the machining of the workpiece during use. However, during the machining process, due to the difference in materials, it will affect the mechanical wave data to be measured.

[0127] Therefore, if Figure 6 As shown, in some embodiments, step S1 may include:

[0128] After the working tool processes the working workpiece for a set time, the mechanical wave data to be measured generated by the working tool in the process of processing the working workpiece is collected at a set frequency, and it is determined whether the mechanical wave data to be measured exceeds a normal working range.

[0129] By setting the collection of the mechanical wave data to be measured after a set time has passed since the working tool started processing, the mechanical waves generated by the tool to be measured during the wear of the protective layer 31 can be effectively filtered out, avoiding the influence of the mechanical waves corresponding to the protective layer 31 on the judgment result.

[0130] In some embodiments, the set time may be greater than or equal to 3 seconds and less than or equal to 10 seconds. For example, it may be 3.5 seconds, 4 seconds, 4.5 seconds, 5 seconds, 5.5 seconds, 6 seconds, 6.5 seconds, 7 seconds, 7.5 seconds, 8 seconds, 8.5 seconds, 9 seconds, 9.5 seconds, or any other value within the range.

[0131] It should be understood that in step S2, the warning signal outputted may include a display signal and / or a sound signal to remind the operator that the tool needs to be replaced. And / or, the warning signal may also include an electrical signal or a wireless signal, which is directly transmitted to the CNC machining device through an electrical connection or a wireless connection. After receiving the warning signal, the CNC machining device may stop the operation to facilitate the operator to replace the tool. No specific limitation is made here.

[0132] It should be understood that the tool replacement warning device 10 constructed in the present application can execute the tool replacement warning method in any of the aforementioned embodiments.

[0133] like Figure 7As shown, in some embodiments, the main control mechanism 11 may include a collection module 111 and a receiving module 112 .

[0134] The acquisition module 111 may be electrically connected to the state detection mechanism 12 to receive the mechanical wave data and the mechanical wave data to be measured collected by the state detection mechanism 12 , and may convert the data into wireless signals for wireless transmission to the receiving module 112 .

[0135] The receiving module 112 can receive the wireless signal and obtain and store the normal operation interval according to the wireless signal of the mechanical wave data. It can also determine whether the mechanical wave data to be tested exceeds the corresponding normal operation interval according to the wireless signal of the mechanical wave data to be tested. When the mechanical wave data to be tested exceeds the normal operation interval, the receiving module 112 can also output an early warning signal.

[0136] Of course, if the test tool includes multiple materials and / or the test workpiece includes multiple materials, the receiving module 112 can also establish a data model based on the material of each test tool and / or the material of each test workpiece, and the normal operating range of its corresponding transition layer.

[0137] Or, for the case where the mechanical wave data includes frequency data and amplitude data, the normal operation interval includes the frequency interval and the amplitude interval, and the mechanical wave data to be tested includes the frequency data to be tested and the amplitude data to be tested, the receiving module 112 can also set the alarm threshold according to the material of the test tool and / or the material of the test workpiece. It can also obtain the frequency data to be tested and the amplitude data to be tested based on the received mechanical wave data to be tested, and calculate the proportion of the number exceeding the frequency interval and the amplitude interval based on the frequency data to be tested and the amplitude data to be tested. It can also determine whether the proportion of the number is greater than the alarm threshold. When the proportion of the number is greater than the alarm threshold, it can output a warning signal.

[0138] By setting the main control mechanism 11 as two modules, namely the acquisition module 111 and the receiving module 112, only the acquisition module 111 and the status detection mechanism 12 of the tool replacement warning device 10 can be set in the fixture 20 of the CNC machining device, further reducing the space occupied in the fixture 20.

[0139] Continue reading Figure 7 In some embodiments, the receiving module 112 may include a signal receiving unit 1121, a first processing unit 1122, a display unit 1123, and an output control unit 1124. The signal receiving unit 1121, the display unit 1123, and the output control unit 1124 may be electrically connected to the first processing unit 1122, respectively.

[0140] The signal receiving unit 1121 is used to receive wireless signals and convert them into electrical signals.

[0141] Specifically, the signal receiving unit 1121 can use an existing BLE (Bluetooth Low Energy) embedded circuit module to receive wireless signals. At the same time, it can also convert the wireless signal into an electrical signal, decompress the compressed electrical signal, and output it to the first processing unit 1122 in the form of a decompressed electrical signal.

[0142] The first processing unit 1122 can store the normal operation interval and receive the electrical signal of the signal receiving unit 1121. It can also judge whether the corresponding mechanical wave data to be tested exceeds the normal operation interval according to the electrical signal. When the mechanical wave data to be tested exceeds the normal operation interval, it can also output a warning signal.

[0143] Specifically, the first processing unit 1122 can use an existing M4 embedded processor to implement data storage and analysis. Of course, in some other optional embodiments, it can also use other types of processors such as ARM processors to implement its functions.

[0144] The display unit 1123 can be used to display the mechanical wave data and the normal operation range. Of course, in some other embodiments, it can also be used to output a warning prompt according to the warning signal to remind the user to manually shut down the CNC machining device and replace the tool 30.

[0145] In some other optional embodiments, the receiving module 112 may also be provided with an early warning unit, which may output a warning prompt such as sound or light when receiving an early warning signal by using structures such as a speaker and a warning light, so as to remind the user to manually shut down the CNC machining device and replace the tool 30.

[0146] The output control unit 1124 can be electrically or wirelessly connected to the CNC machining device to receive the warning signal and output a stop operation signal to the CNC machining device in the form of an electrical signal or a wireless signal. The CNC machining device can stop the machining operation to replace the tool 30 after receiving the warning signal.

[0147] In some embodiments, the receiving module 112 may further include a first power supply unit 1125 , which may be electrically connected to the first processing unit 1122 to provide power for the operation of the receiving module 112 .

[0148] In some embodiments, the acquisition module 111 may include a second processing unit 1111, a second power supply unit 1112, and a signal transmission unit 1113. The state detection mechanism 12, the second power supply unit 1112, and the signal transmission unit 1113 are electrically connected to the second processing unit 1111, respectively. The second power supply unit 1112 can provide power for the operation of the acquisition module 111 and the state detection mechanism 12. The first processing unit can receive the mechanical wave data and the mechanical wave data to be measured collected by the state detection mechanism 12, and transmit them to the signal transmission unit 1113 in the form of electrical signals. The signal transmission unit 1113 can convert them into wireless signals and output them.

[0149] Specifically, the second processing unit 1111 can be implemented by an existing embedded processor, which can receive the electrical signal output by the state detection mechanism 12 and compress it so that the signal transmission unit 1113 can perform wireless signal transmission.

[0150] The signal transmission unit 1113 can be implemented using an existing BLE (Bluetooth Low Energy) wireless transmission unit.

[0151] Of course, in some other optional embodiments, the signal transmission unit 1113 and the signal receiving unit 1121 can also be implemented using other existing wireless communication technologies such as Wi-Fi (wireless LAN communication technology), Zigbee (Zigbee protocol), NB-IoT (narrowband Internet of Things), and LoRa (long range radio).

[0152] like Figure 8 As shown, the present application also constructs a CNC machining system 1, which may include a CNC machining device and a tool replacement warning device 10 in any of the aforementioned embodiments.

[0153] The numerical control processing device may include a machine tool (not shown in the figure), a fixture 20 and a tool 30. The fixture 20 is arranged on the machine tool, and may be hollow inside, for coaxially arranging the tool 30. The tool 30 is detachably arranged on the fixture 20, and the workpiece is arranged on the machine tool. Through the control of the machine tool, the fixture 20 can drive the tool 30 to perform processing operations on the workpiece.

[0154] Among them, at least part of the tool replacement warning device 10 can be set on the machine tool, and / or on the fixture 20, and / or on the tool 30.

[0155] Read also Fig. 9 In some embodiments, the tool replacement warning device 10 may further include a housing 15, which may accommodate the state detection mechanism 12 and at least a portion of the main control mechanism 11, so as to facilitate its integration on the CNC machining device.

[0156] In some embodiments, the main control mechanism 11 may further include a main control board 113, and the acquisition module 111 is arranged on the main control board 113. It is arranged in the housing 15 together with the state detection mechanism 12, and is integrated to form a detection part. The receiving module 112 can be separately arranged outside the housing 15 and outside the fixture 20, so as to facilitate the operation of the operator. Such a setting can also reduce the volume of the housing 15, thereby reducing the volume occupied by the fixture 20.

[0157] Of course, in some other optional embodiments, the receiving module 112 may also be disposed in the fixture 20 and transmit the control signal to the CNC machining device through wireless communication.

[0158] Furthermore, at least two assembly slots 21 may be evenly spaced along the circumference of the fixture 20. The CNC machining system 1 may include at least two tool replacement warning devices 10, and the detection part of each tool replacement warning device 10 may be respectively disposed in the assembly slots 21.

[0159] By providing at least two assembly grooves 21 on the fixture 20 and arranging them evenly spaced along the circumference, the center of gravity of the fixture 20 structure can be maintained on its axis, thereby avoiding affecting the fixture 20 from rotating to drive the tool 30 to perform processing operations.

[0160] By arranging the detection part on the fixture 20, the transmission of mechanical waves can be realized through the physical contact between the tool 30 and the fixture 20, and then the collection of mechanical waves can be realized, so as to improve the accuracy of the collected mechanical waves.

[0161] At the same time, the setting of at least two tool replacement warning devices 10 can respectively test the mechanical wave data in the operation process to monitor and warn respectively. Such a setting can prevent a single tool replacement warning device 10 from being damaged during the operation process, affecting the accuracy of the warning monitoring.

[0162] It should be understood that the at least two tool replacement warning devices 10 may share the same receiving module 112 , or may each be provided with a separate receiving module 112 , which is not specifically limited herein.

[0163] exist Figure 8 In the illustrated embodiment, the number of the assembly slots 21 and the number of the tool replacement warning device 10 are two respectively. The two assembly slots 21 are symmetrically arranged on the fixture 20 .

[0164] Of course, in some other optional embodiments, the number of the assembly slots 21 and the tool replacement warning device 10 can also be set to three, four or more. Or, the number of the tool replacement warning device 10 can be set to one, and the assembly slot 21 can be correspondingly set at a position symmetrical to the position where the fixture 20 is set, and a structural block with the same volume and weight as the detection part of the tool replacement warning device 10 is configured therein to ensure that the center of gravity of the fixture 20 is located on its axis.

[0165] In some other optional embodiments, the detection structure can also be set on the machine tool, and the mechanical wave generated between the workpiece and the tool can be collected through the mechanical wave transmission between the workpiece and the machine tool. Alternatively, part of the detection structure of the tool replacement warning device 10 can be set on the fixture 20, and the remaining part can be set on the tool 30, or the remaining part can be set on the machine tool, etc.

[0166] like Fig. 9 As shown, in some embodiments, the housing 15 may include an inner housing 151 and an outer housing 152, which may be detachably connected to facilitate the assembly of the acquisition module 111, the main control board 113, and the state detection mechanism 12. When the detection structure is assembled into the assembly slot 21, the housing 15 is embedded in the assembly slot 21, and the inner housing 151 is adjacent to the slot wall of the assembly slot 21, and part of the outer housing 152 is detachably connected to the slot wall of the assembly slot 21 of the fixture 20. The remaining part of the outer housing 152 is exposed in the assembly slot 21 and smoothly connected to the outer contour of the fixture 20.

[0167] In some other optional embodiments, the shell 15 may also be buried in the fixture 20 , with the inner shell 151 and the outer shell 152 respectively attached to the walls of the assembly chamber inside the fixture 20 .

[0168] By embedding or burying the detection structure in the fixture 20, the influence of machine noise in the working environment and environmental noise on the mechanical wave collected by the state detection mechanism 12 can be reduced during the operation of the CNC machining device, and the mechanical waves generated by the friction between the tool 30 and the workpiece can be accurately collected to further improve the accuracy of monitoring and early warning.

[0169] like Figure 8As shown, in some embodiments, the main control board 113 is arranged parallel to the axis of the fixture 20, and the state detection mechanism 12 is arranged on the main control board 113, and is clamped between the main control board 113 and the inner shell 151. When the detection structure of the tool replacement warning device 10 is assembled into the assembly groove 21, the setting position of the state detection mechanism 12 enables it to indirectly contact the groove wall of the assembly groove 21 of the fixture 20 through the inner shell 151. Such a setting enables the state detection mechanism 12 to more accurately detect the friction between the tool 30 and the workpiece during the operation of the CNC machining device through physical contact, thereby realizing the precise collection of mechanical waves.

[0170] Furthermore, the signal transmission unit 1113 in the acquisition module 111 can be arranged on the side of the main control board 113 facing the shell 152 to output the wireless signal outside the fixture 20 to avoid being affected by other electrical components in the shell 15.

[0171] Specifically, the signal transmission unit 1113 can be directly disposed on the main control board 113, or a separate mounting plate can be separately disposed in parallel with the main control board 113 and spaced apart from each other. No specific limitation is made here.

[0172] In some embodiments, the second power supply unit 1112 may include at least one battery, which may be arranged on the same side of the main control board 113 as the status detection mechanism 12 , and the second processing unit 1111 is arranged on the opposite side to improve the utilization rate of the main control board 113 .

[0173] Of course, in some other optional embodiments, the second power supply unit 1112 can also be arranged on the same side as the second processing unit 1111, or the second processing unit 1111 and the status detection mechanism 12 can be arranged on the same side of the main control board 113.

[0174] It can be understood that the above-mentioned technical features can be used in any combination without limitation.

[0175] The above embodiments only express the specific implementation methods of the present application, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the patent of the present application. It should be pointed out that, for ordinary technicians in this field, without departing from the concept of the present application, the above technical features can be freely combined, and several deformations and improvements can be made, which all belong to the protection scope of the present application. Therefore, all equivalent changes and modifications made to the scope of the claims of the present application should belong to the scope covered by the claims of the present application.

Claims

1. A tool replacement warning method, applied to a tool replacement warning device; the tool comprises a functional layer and a transition layer; the tool replacement warning device stores a normal operation range of mechanical wave data when the tool normally processes a workpiece; characterized in that: The tool replacement early warning method comprises the steps of: S1: collecting the mechanical wave data to be measured generated by the working tool during the processing of the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the normal working range; S2: When the mechanical wave data to be measured exceeds the normal operation range, output a warning signal.

2. The tool replacement early warning method according to claim 1, characterized in that: The tool replacement warning device stores a data model, and the data model includes materials of the tools of various materials and their corresponding normal working ranges; The step S1 comprises: S11, obtaining the material of the working tool, and selecting the corresponding normal working range in the data model according to the material of the working tool; S12, collecting the mechanical wave data to be measured generated by the working tool during the processing of the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the corresponding normal working range.

3. The tool replacement early warning method according to claim 2, characterized in that: The step S1 comprises: S11, obtaining the material of the working tool, and judging whether the material of the working tool belongs to the material in the data model according to the material of the working tool; S121, if the material belongs to the data model, then according to the material of the working tool, select the corresponding normal working range in the data model; S122, collecting the mechanical wave data to be measured generated by the working tool during the process of machining the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the corresponding normal working range; S131, if the material does not belong to the data model, obtaining mechanical wave data generated by the working tool when processing the working workpiece; S132, obtaining the normal operation range of the operation tool according to the mechanical wave data; S133, updating the material and the corresponding normal operation range into the data model.

4. The tool replacement early warning method according to claim 2, characterized in that: The data model includes the materials of the cutting tools of various materials, the materials of the workpieces of various materials, and the normal working ranges corresponding to the material combinations thereof; The step S1 comprises: S11, obtaining the material of the working tool and the material of the working workpiece, and selecting the corresponding normal working range in the data model according to the combination of the material of the working tool and the material of the working workpiece; S12, collecting the mechanical wave data to be measured generated by the working tool during the process of machining the working workpiece at a set frequency, and determining whether the mechanical wave data to be measured exceeds the corresponding normal working range.

5. The tool replacement early warning method according to claim 1, characterized in that: The normal operation range includes a frequency range and an amplitude range; The mechanical wave data to be measured includes amplitude data to be measured and frequency data to be measured; the tool replacement warning device stores an alarm threshold; The step S1 comprises: S11, collecting the frequency data to be measured and the amplitude data to be measured generated by the working tool in the process of machining the working workpiece at a set frequency, and calculating the proportion of the frequency data to be measured and the amplitude data to be measured exceeding the frequency interval and the amplitude interval within a collection period; S12, determining whether the quantity ratio is greater than an alarm threshold; The step S2 comprises: When the quantity ratio is greater than the alarm threshold, an early warning signal is output.

6. The tool replacement early warning method according to claim 1, characterized in that: The step S1 comprises: After the working tool processes the working workpiece for a set time, the mechanical wave data to be measured generated by the working tool in the process of processing the working workpiece is collected at a set frequency, and it is determined whether the mechanical wave data to be measured exceeds the normal working range.

7. A tool replacement warning device, characterized in that: include: A state detection mechanism (12) is used to collect the mechanical wave data to be measured generated by the working tool during the process of machining the working workpiece at a set frequency; The main control mechanism (11) stores the normal operating range and is electrically connected to the state detection mechanism (12); it is used to receive the mechanical wave data to be tested and determine whether the mechanical wave data to be tested exceeds the normal operating range, so as to output a warning signal when the mechanical wave data to be tested exceeds the normal operating range.

8. The tool replacement warning device according to claim 7, characterized in that: The main control mechanism (11) comprises a collection module (111) and a receiving module (112); The acquisition module (111) is electrically connected to the state detection mechanism (12), and is used to receive the mechanical wave data to be measured, convert it into a wireless signal, and wirelessly transmit it to the receiving module (112); The receiving module (112) stores the normal operating range and is used to receive the wireless signal and determine whether the corresponding mechanical wave data to be tested exceeds the normal operating range based on the wireless signal, so as to output a warning signal when the mechanical wave data exceeds the normal operating range.

9. The tool replacement warning device according to claim 7, characterized in that: The state detection mechanism (12) is also used to obtain mechanical wave data of the test tool when processing the test workpiece; and the main control mechanism (11) is also used to obtain and store the normal operation range according to the mechanical wave data.

10. A numerical control machining system, characterized in that: It comprises a numerical control machining device and at least one tool replacement warning device (10) as described in any one of claims 7 to 9; the numerical control machining device comprises a machine tool, a fixture (20) and a tool (30); the fixture (20) is arranged on the machine tool, and the tool (30) is detachably arranged on the fixture (20); at least part of the tool replacement warning device (10) is arranged on the machine tool, and / or the fixture (20), and / or the tool (30).

11. The numerical control machining system according to claim 10, characterized in that: At least a portion of the tool replacement warning device (10) is embedded or buried in the fixture (20).

12. The numerical control machining system according to claim 11, characterized in that: The number of the tool replacement warning devices (10) is at least two, and they are evenly spaced along the circumference of the clamp (20).

13. The numerical control machining system according to claim 11, characterized in that: An assembly groove (21) is formed on the fixture (20); the tool replacement warning device (10) also includes a shell (15) embedded in the assembly groove (21); at least part of the main control mechanism (11) and the state detection mechanism (12) are respectively arranged in the shell (15), and the state detection mechanism (12) is arranged on a side of the main control mechanism (11) close to the groove wall of the assembly groove (21), and is arranged adjacent to the groove wall of the assembly groove (21) through the shell (15).

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