Multi-machine-tool centralized management and control system and centralized management and control method

Abstract

The invention relates to a centralized management and control system for multiple machine tools. The centralized management and control system comprises a plurality of control parts and a plurality of monitoring parts which are in one-to-one correspondence with a plurality of machine tools; the control part comprises a first control unit and a second control unit, and the first control unit is connected into a control system of the machine tool and used for controlling the machine tool on site; the second control unit is arranged in a control room, is in butt joint with the first control unit through a workshop equipment network and is used for remotely controlling a machine tool; the monitoring part comprises a measuring unit and a monitoring unit, the measuring unit is integrated on the machine tool, and the monitoring unit is arranged in the control chamber and is in butt joint with the measuring unit. According to the multi-machine-tool centralized management and control system, original programs of the machine tools do not need to be changed, centralized remote monitoring and control over the multiple machine tools can be achieved in a simple access mode, the problem expansion caused by unexpected field care is avoided, one person controls indoor guarding, the overall number of people is reduced, and the comprehensive efficiency of the personnel is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of processing equipment control, and in particular to a centralized control system and a centralized control method for multiple machine tools. Background Art

[0002] In the field of mechanical processing technology, medium and large workpieces are often processed using CNC machine tools. After the program is set, the processing time is basically measured in days. One machine tool equipment often requires one person to be on duty to stop, inspect, and adjust the machine at any time when an abnormality or emergency occurs. Even for two or three machine tools with a small spacing, one person can take care of the duty, but for large processing workshops, a large number of on-duty personnel are still required, and the utilization rate of personnel is too low.

[0003] Existing technical centers can use analytical models to predict machine tool failures in advance, but this analytical model requires a high technical threshold, supporting server computing power and model algorithms, which are beyond the reach of ordinary small and medium-sized enterprises, and parameter tuning requires a large amount of data and time accumulation. Since machine tools often have several processing procedures, the processing process changes tools according to the process, and the types, characteristics, and wear of tools are different. The reality is that each process has its own particularity, and it is difficult to unify the threshold adjustment. There are a large number of false alarms and missed alarms, which cause great interference to normal processing and real abnormal confirmation; when there is a real problem in the processing process, it is impossible to stop the machine, emergency stop, and adjust the spindle rate and feed rate in time, making it difficult to achieve remote control, and the number of on-site supervisors cannot be reduced. In addition, the prediction model cannot predict the current requirements for the material, specifications, precision, etc. of the workpiece, as well as whether the tools are mixed. It can only be used for monitoring the processing process of large quantities of uniform workpiece specifications, and is not applicable to the processing of small batches of workpieces of multiple varieties. For example, before the prediction model is learned, the workpiece of this variety has been processed and there is no follow-up. Summary of the invention

[0004] Based on this, it is necessary to provide a multi-machine tool centralized control system and a multi-machine tool centralized control method that does not require changing the original machine tool program, has a low transformation threshold and a simple access method to address the above-mentioned technical problems.

[0005] In order to solve the above problems, the present invention adopts the following technical solutions:

[0006] An embodiment of the present invention discloses a centralized control system for multiple machine tools, including multiple control units and multiple monitoring units corresponding to multiple machine tools respectively; the control unit includes a first control unit and a second control unit, the first control unit is connected to the control system of the machine tool, and is used to control the machine tool on site; the second control unit is arranged in a control room and is connected to the first control unit through a workshop equipment network, and is used to remotely control the machine tool; the monitoring unit includes a measuring unit and a monitoring unit, the measuring unit is integrated on the machine tool, and the monitoring unit is arranged in the control room and is connected to the measuring unit.

[0007] In one embodiment, the measuring unit includes two cameras and a noise sensor; one camera is arranged at the far tool part of the machine tool to monitor the overall condition of the machine tool; the other camera is arranged at the near tool part of the machine tool to monitor the processing condition of the machine tool; the noise sensor is arranged on or around the machine tool to monitor the machine tool based on the noise.

[0008] In one embodiment, the measuring unit further comprises a temperature vibration sensor disposed on a spindle of the machine tool, for monitoring the machine tool according to the temperature vibration of the spindle.

[0009] In one embodiment, the monitoring unit includes a video monitoring screen and a configuration monitoring screen, wherein the video monitoring screen is connected to the camera; and the configuration monitoring screen is connected to the noise sensor and / or the temperature and vibration sensor.

[0010] In one embodiment, the configuration monitoring screen is also connected to the data acquisition unit of the machine tool itself to display the main CNC operation interface of the machine tool.

[0011] In one of the embodiments, the centralized control system also includes a master control PLC connected to the workshop equipment network, and multiple second control units are connected to the master control PLC; the second control unit includes a control box connected to the master control PLC, the control box is provided with start, stop, emergency stop and ratio adjustment keys, and a second IO module is connected between the control box and the master control PLC.

[0012] In one embodiment, the monitoring unit further includes a three-color signal light, and the three-color signal light is connected to the master control PLC.

[0013] In one embodiment, a switch is provided between the first control unit and the second control unit; when the switch is in an off state, remote control of the machine tool is prohibited; when the switch is in an on state, the machine tool can be remotely controlled; the priority of the first control unit and the second control unit is based on the most recent action.

[0014] In one embodiment, the first control unit includes a sub-control PLC, a multiplier switch and a start-stop switch, one end of the sub-control PLC is connected to the workshop equipment network, and the other end is connected to the multiplier switch and the start-stop switch; the first control unit also includes a first IO module, and the first IO module is connected between the sub-control PLC and the multiplier switch.

[0015] In one embodiment, the centralized control system further includes a large display screen, which is arranged in the workshop and connected to the monitoring unit.

[0016] In a second aspect, an embodiment of the present invention further discloses a method for centralized control of multiple machine tools, using the centralized control system for multiple machine tools described in any of the above embodiments, the centralized control method comprises the following steps:

[0017] Centralized remote monitoring: multiple monitoring units can be used to monitor the operation of multiple machine tools;

[0018] Centralized remote control: Based on the monitoring data of the monitoring unit, the machine tool corresponding to the second unit is remotely controlled through the second control unit.

[0019] The technical solution adopted by the present invention can achieve the following beneficial effects:

[0020] The centralized control system for multiple machine tools disclosed in the present invention is configured with a second control unit and a monitoring unit integrated in the control room for each machine tool. In conjunction with the measurement unit integrated on the machine tool and the data acquisition software of the machine tool itself, the staff can centrally monitor and remotely control all machine tools in the control room to improve the utilization rate of personnel. The centralized control system for multiple machine tools disclosed in the present invention, in addition to the CNC panel master data, synchronizes the video monitoring in the control room with the SCADA data, takes into account abnormal conditions such as machine tool images, noise, vibration, etc., and monitors them in a graphical, curved, and digital manner according to the flexibly adjustable threshold value, and is supplemented by sound and light alarm reminders. When an abnormality occurs, the remote control personnel can remotely shut down, emergency stop, switch the spindle ratio and feed ratio, avoid the problem from being magnified due to poor on-site care, and realize one person on duty in the control room, so as to achieve overall reduction in personnel and improve the overall efficiency of personnel.

[0021] The multi-machine tool centralized control system disclosed in the present invention makes full use of the communication interface and link resources of the master control PLC and the sub-control PLC, and can minimize the control cost while meeting the centralized monitoring and remote control requirements; in the electromechanical implementation process, only the original electrical circuit is connected in series or in parallel in the CNC operation box or the main electrical cabinet of the machine tool, and the original machine tool control program is not changed, that is, there is no need to modify the machine tool program, and the technical threshold is extremely low, and ordinary electrical engineers can be competent. In addition, the multi-machine tool centralized control system disclosed in the present invention has strong scalability, and each unit and component of the system can be configured for complete set of replication expansion according to the scale of the workshop. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A schematic diagram of a centralized control system for multiple machine tools disclosed in an embodiment of the present invention;

[0023] Figure 2 It is a connection diagram of a machine tool control switch in the prior art;

[0024] Figure 3 A schematic diagram of the access of control components of a multi-machine tool centralized control system disclosed in an embodiment of the present invention. DETAILED DESCRIPTION

[0025] In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The preferred embodiments of the present invention are given in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0026] It should be noted that when an element is referred to as being "disposed on" another element, it may be directly on the other element or there may be a centered element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a centered element at the same time. The terms "vertical", "horizontal", "left", "right", "top", "bottom", "bottom end", "top end" and similar expressions used herein are for illustrative purposes only and are not intended to be the only implementation method.

[0027] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used herein in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0028] The embodiment of the present invention discloses a multi-machine tool centralized control system, which is used for centralized remote monitoring and control of multiple machine tools. The disclosed multi-machine tool centralized control system includes multiple control units and multiple monitoring units, and the number of control units and monitoring units should correspond to the number of machine tools; each machine tool corresponds to a monitoring unit, which is used to remotely monitor key data such as the machine tool operation status; each machine tool corresponds to a control unit, and the on-duty personnel can remotely control the machine tool in the control room according to the machine tool data monitored by them.

[0029] In order to better understand the concept of the present invention, this embodiment takes two machine tools as an example to explain in detail the centralized control system for multiple machine tools disclosed in the present invention. Of course, the centralized control system for multiple machine tools disclosed in the present invention is not limited to monitoring only two machine tools, and each monitoring or control component, module, unit, etc. can be expanded as a set to monitor more machine tools, and the embodiment of the present invention does not make specific restrictions on this.

[0030] like Figure 1As shown, the workshop is equipped with 1# machine tool and 2# machine tool, and the control room is centrally equipped with the 1# machine tool remote monitoring unit for remote control of 1# machine tool and the 2# machine tool remote monitoring unit for remote control of 2# machine tool. The 1# machine tool remote monitoring unit is equipped with a video monitoring screen and a configuration monitoring screen for monitoring the key data of 1# machine tool, and a control box for remote control of 1# machine tool. The control box is equipped with stop, start, emergency stop buttons and a magnification switching knob. Similarly, the 2# machine tool remote monitoring unit is also equipped with the same video monitoring screen, configuration monitoring screen and control box as the 1# machine tool remote monitoring unit. Only one on-duty personnel can be arranged in the control room to centrally monitor the operating status of 1# machine tool and 2# machine tool, and remotely stop, start, emergency stop and adjust and switch 1# machine tool and 2# machine tool.

[0031] In order to realize remote monitoring of machine tool #1, a monitoring unit corresponding to machine tool #1 is set, and the monitoring unit includes a monitoring unit and a measuring unit connected to the monitoring unit. The monitoring unit may include a video monitoring screen and a configuration monitoring screen, and the video monitoring screen and the configuration monitoring screen are connected to the same computer host. The measuring unit is integrated in machine tool #1, including two cameras, a noise sensor and a temperature vibration sensor. One of the cameras is set near the tool head of the machine tool, so as not to interfere with normal processing and the angle is adjusted to always monitor the tool head part, and is used to shoot the tool condition; the other camera is set above the machine tool to shoot the whole picture of the machine tool and its surrounding environment; the image data captured by the two cameras are transmitted to the computer host through the workshop video network and displayed synchronously on the video monitoring screen. The camera is preferably a video high-definition shooting device with night vision function. The noise sensor is wall-mounted on the side wall of the CNC operation box of the 1# machine tool to obtain the real-time noise decibel value of the 1# machine tool, and output the reminder and alarm status corresponding to the high decibel value according to the set threshold; the temperature vibration sensor can be installed above the spindle motor or processing spindle component of the 1# machine tool, so as not to interfere with normal processing, and at the same time provide the time domain characteristic values ​​(RMS value, peak value) of the vibration velocity and vibration acceleration in the three directions of X, Y, and Z, the time domain characteristic values ​​(RMS value, peak-to-peak value) of the displacement, the spectrum analysis results, the envelope spectrum analysis results, the early warning alarm and the real-time value of the temperature of the measured point. The 1# machine tool is also equipped with a sub-control PLC connected to the noise sensor and the temperature vibration sensor. The sub-control PLC transmits the noise and temperature vibration data of the 1# machine tool it receives to the computer host through the workshop equipment network and displays it on the configuration monitoring screen. In addition, the workshop equipment network is also connected to the data acquisition server of the 1# machine tool itself, and the computer host can display the CNC main operation interface of the 1# machine tool on the configuration monitoring screen through the workshop equipment network.

[0032] In order to realize the remote control of machine tool 1#, a master control PLC and a control unit corresponding to machine tool 1# are set. The control unit includes a first control unit connected to the original control system of machine tool 1# and a second control unit set in the control room. The first control unit is connected to the master control PLC through the workshop equipment network, and the master control PLC is connected to the second control unit. The first control unit may include a control switch, a first IO module, and a sub-control PLC connected to the two. The control switch includes the original multiplier switch and start-stop switch of machine tool 1#, and the first IO module may be an RS485 IO module. The specific modification method is as follows: Figure 2 , Figure 3 As shown, the ratio switch and the start-stop switch of the 1# machine tool were originally connected to the MPC main control board of the 1# machine tool. The start-stop switch is provided with stop, start and emergency stop buttons, and the ratio switch is a knob key, which is used to switch the ratio of the machine tool. In this embodiment, the first IO module is connected between the ratio switch and the MPC main control board, and the first IO module and the start-stop switch are both connected to the sub-control PLC. The first control unit is thus connected to the control system of the machine tool, and the operation of the ratio switch and the start-stop switch can be fed back to the remote control unit of the 1# machine tool through the sub-control PLC and the workshop equipment network.

[0033] The second control unit is a remote control unit, which includes a control box and a second IO module. The second IO module can be a PNIO slave module. The control box is connected to the master control PLC through the PN IO slave module. The master control PLC is connected to the first control unit through the workshop equipment network to realize remote control of stopping, starting, emergency stopping and ratio switching of the machine tool through the control box in the control room.

[0034] Furthermore, the remote monitoring unit of machine tool 1# can also be equipped with a three-color sound and light signal light, which is connected to the master control PLC through the PN IO slave module. According to the operation status of the machine tool, the three-color sound and light signal light will synchronously give sound and light alarm reminders to prevent fatigue and slow response from staring at the screen for a long time.

[0035] In the embodiments disclosed in the present invention, the monitoring unit and control unit of the 2# machine tool can adopt the same configuration as the 1# machine tool described in any of the above embodiments, and this embodiment will not be repeated. Of course, the remote control modules and units of the 1# machine tool and the 2# machine tool can be connected to the same master control PLC.

[0036] In the embodiment disclosed in the present invention, a remote switch may be provided between the first control unit and the second control unit of the 1# machine tool or the 2# machine tool. When the remote switch is in the disconnected state, the 1# machine tool or the 2# machine tool is in a remote control prohibited state, and the remote control function of its second control unit is turned off. When the remote switch is in the connected state, the 1# machine tool or the 2# machine tool is in a remote control permitted state, and the machine tool can be controlled by its first control unit and the second control unit, and the priority of the two is based on the most recent action.

[0037] In the embodiment disclosed in the present invention, the centralized control system may further include a large display screen arranged in the workshop, which is connected to the workshop video network and the workshop equipment network to display the monitoring data of each machine tool and the CNC main operation interface data.

[0038] In a second aspect, an embodiment of the present invention further discloses a method for controlling multiple machine tools. Using the centralized control system described in any of the above embodiments, the method for controlling multiple machine tools may include the following steps:

[0039] S1. Centrally monitor the operating status of each machine tool in the control room through the video monitoring screen and configuration monitoring screen;

[0040] S2. Based on the monitoring situation, use the control box to remotely control the corresponding machine tool.

[0041] The above-mentioned embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A centralized control system for multiple machine tools, characterized in that: It includes a plurality of control units and a plurality of monitoring units corresponding to the plurality of machine tools respectively; The control unit includes a first control unit and a second control unit, wherein the first control unit is connected to the control system of the machine tool and is used to control the machine tool on site; the second control unit is arranged in the control room and is connected to the first control unit through the workshop equipment network and is used to remotely control the machine tool; The monitoring unit includes a measuring unit and a monitoring unit. The measuring unit is integrated on the machine tool. The monitoring unit is arranged in the control room and docked with the measuring unit.

2. The multi-machine tool centralized control system according to claim 1, characterized in that: The measuring unit includes two cameras and a noise sensor; One camera is arranged at a far tool portion of the machine tool, and the other camera is arranged at a near tool portion of the machine tool; The noise sensor is arranged on or around the machine tool; The measuring unit further comprises a temperature vibration sensor, and the temperature vibration sensor is arranged on the main shaft of the machine tool.

3. The multi-machine tool centralized control system according to claim 2 is characterized in that: The monitoring unit includes a video monitoring screen and a configuration monitoring screen. The video monitoring screen is connected to the camera; the configuration monitoring screen is connected to the noise sensor and / or the temperature and vibration sensor.

4. The multi-machine tool centralized control system according to claim 3 is characterized in that: The configuration monitoring screen is connected to the data acquisition unit of the machine tool itself.

5. The multi-machine tool centralized control system according to claim 1, characterized in that: The centralized control system also includes a master control PLC connected to the workshop equipment network, and a plurality of second control units are connected to the master control PLC; The second control unit includes a control box connected to the master control PLC, the control box is provided with start, stop, emergency stop and ratio adjustment keys, and a second IO module is connected between the control box and the master control PLC.

6. The multi-machine tool centralized control system according to claim 5, characterized in that: The monitoring unit also includes a three-color signal light, and the three-color signal light is connected to the master control PLC.

7. The multi-machine tool centralized control system according to claim 1, characterized in that: A switch is provided between the first control unit and the second control unit; When the switch is in the off state, the machine tool is prohibited from remote control; When the switch is in the connected state, the machine tool can be remotely controlled; the priority of the first control unit and the second control unit is based on the most recent action.

8. According to the centralized control system for multiple machine tools in claim 1, the first control unit comprises a sub-control PLC, a rate switch and a start-stop switch, one end of the sub-control PLC is connected to the workshop equipment network, and the other end is connected to the rate switch and the start-stop switch; The first control unit also includes a first IO module, and the first IO module is connected between the sub-control PLC and the multiplier switch.

9. The multi-machine tool centralized control system according to claim 1, characterized in that: The centralized control system also includes a large display screen, which is arranged in the workshop and connected to the monitoring unit.

10. A method for centralized control of multiple machine tools, using the centralized control system for multiple machine tools as claimed in any one of claims 1 to 9, characterized in that: The centralized control method comprises the following steps: Centralized remote monitoring: multiple monitoring units can be used to monitor the operation of multiple machine tools; Centralized remote control: Based on the monitoring data of the monitoring unit, the machine tool corresponding to the second unit is remotely controlled through the second control unit.

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