Workpiece clamping force monitoring system for a clamp

Abstract

The present disclosure provides a workpiece clamping force monitoring system for a clamp, belonging to the technical field of tooling clamps. The workpiece clamping force monitoring system for the clamp comprises a plurality of sensor modules for monitoring the pressure information of the workpiece when the clamp clamps the workpiece in real time and transmitting the pressure information to a data processing module. The data processing module can transmit the processed pressure data to a central control module through a first communication module. The central control module can transmit the data information to a display module to display the pressure fluctuation curve, and can also intelligently analyze the plurality of pressure information to determine a target adjustment strategy. When the pressure information is abnormal, the first alarm module is triggered, an alarm is given and emergency shutdown measures are taken. The workpiece clamping force monitoring system for the clamp provided by the present disclosure can improve the control accuracy, accuracy and anti-interference of the clamping force of the clamp, and based on the abnormal pressure information, an alarm is given to avoid causing greater losses, ensure the stability of the machining process and improve the production efficiency.

Description

Technical Field

[0001] This disclosure relates to the field of tooling and fixture technology, and in particular to a workpiece clamping force monitoring system for a fixture. Background Technology

[0002] In industries such as automotive manufacturing, machining, and electronics manufacturing, tooling fixtures are specialized tools used to fix, clamp, and support workpieces. These fixtures play a crucial role in manufacturing, particularly in ensuring the stability and accuracy of workpieces during processing. Accurate monitoring and control of workpiece clamping force is a vital link in ensuring product quality and safe production. However, clamping force measurement is easily affected by various environmental factors, leading to problems such as sensor position misalignment and inaccurate data measurement, requiring manual intervention and adjustment, resulting in high manual maintenance costs and low production efficiency. Traditional clamping force monitoring technologies are relatively inadequate in monitoring and identifying abnormal conditions, lacking more intelligent anomaly monitoring and decision support functions. Summary of the Invention

[0003] This disclosure provides a workpiece clamping force monitoring system for fixtures to solve the problems of high manual maintenance costs, low production efficiency, and lack of intelligent anomaly monitoring and auxiliary decision-making functions in clamping force monitoring.

[0004] This disclosure provides a workpiece clamping force monitoring system for a fixture, including: multiple sensor modules, a data processing module, and a central control module.

[0005] Multiple sensor modules are set at different positions on the tooling fixture, and the data processing module is connected to the multiple sensor modules and the central control module respectively.

[0006] Multiple sensor modules are used to collect multiple pressure information at corresponding locations and send the multiple pressure information to the data processing module.

[0007] The data processing module is used to send multiple pressure information to the central control module.

[0008] The central control module is used to determine the target adjustment strategy based on multiple pressure information, and adjust the clamping force of each hydraulic cylinder on the tooling fixture according to the target adjustment strategy.

[0009] In one exemplary embodiment of this disclosure, a workpiece clamping force monitoring system for a fixture further includes a first communication module and a display module.

[0010] The first communication module is connected to both the data processing module and the central control module, and the display module is connected to the central control module.

[0011] The first communication module is used to receive multiple pressure information messages sent by the data processing module and forward these messages to the central control module.

[0012] The central control module is also used to send multiple pressure information to the display module so that the display module can display multiple pressure information.

[0013] In one exemplary embodiment of this disclosure, a workpiece clamping force monitoring system for a fixture further includes a second communication module and a first alarm module.

[0014] The central control module is also connected to the second communication module and the first alarm module, respectively. The second communication module is used to connect to external terminals.

[0015] The central control module is also used to send a first alarm command to the first alarm module when there is abnormal pressure information among multiple pressure information, so that the first alarm module can issue an alarm.

[0016] The central control module is also used to send multiple pressure information messages to an external terminal via a second communication module, and to receive adjustment commands from the external terminal. The adjustment commands are used to instruct the adjustment of the clamping force of each hydraulic cylinder on the tooling fixture.

[0017] In one exemplary embodiment of this disclosure, a workpiece clamping force monitoring system for a fixture further includes a second alarm module. The second alarm module is connected to both the data processing module and the central control module.

[0018] The data processing module is also used to generate a second alarm command based on multiple pressure information and send the second alarm command to the second alarm module so that the second alarm module can issue an alarm.

[0019] The data processing module is also used to generate a second alarm command based on multiple pressure information and send the second alarm command to the central control module.

[0020] In one exemplary embodiment of this disclosure, the data processing module includes a signal processing unit and a comparison unit.

[0021] The signal processing unit is used to convert multiple pressure information into multiple pressure signals, and send the multiple pressure signals to the comparison unit.

[0022] The comparison unit is used to compare multiple pressure signals and multiple standard pressure signals one by one, and generate a second alarm command based on the comparison results, and send the second alarm command to the second alarm module.

[0023] In one exemplary embodiment of this disclosure, the comparison unit includes a first comparison subunit and a second comparison subunit.

[0024] The first comparator subunit includes: amplifier U1, amplifier U2, OR gate H1, transistor Q1, and power supply VCC.

[0025] Amplifier U1 has its non-inverting input connected to the signal processing unit, its inverting input used to receive the reference voltage V1, and its output connected to the first input of OR gate H1.

[0026] Amplifier U2 has its non-inverting input connected to the non-inverting input of amplifier U1, its inverting input used to receive the reference voltage V2, and its output connected to the second input of OR gate H1.

[0027] The output of OR gate H1 is connected to the base of transistor Q1.

[0028] Transistor Q1 has its collector connected to the power supply VCC and its emitter connected to the alarm.

[0029] The second comparator subunit includes: amplifier U3, amplifier U4, OR gate H2, transistor Q2, and power supply VCC.

[0030] Amplifier U3 has its non-inverting input connected to the signal processing unit, its inverting input used to receive the reference voltage V3, and its output connected to the first input of OR gate H2.

[0031] Amplifier U4 has its non-inverting input connected to the non-inverting input of amplifier U3, its inverting input used to receive the reference voltage V4, and its output connected to the second input of OR gate H2.

[0032] The output of OR gate H2 is connected to the base of transistor Q2.

[0033] Transistor Q2 has its collector connected to the power supply VCC and its emitter connected to the alarm.

[0034] In one exemplary embodiment of this disclosure, determining a target adjustment strategy based on multiple pressure information includes:

[0035] Based on the matching relationship between the number of abnormal pressure information in multiple pressure information and multiple adjustment strategies, the target adjustment strategy is determined from multiple adjustment strategies.

[0036] In one exemplary embodiment of this disclosure, the plurality of adjustment strategies include a first adjustment strategy, a second adjustment strategy, and a third adjustment strategy.

[0037] Based on the matching relationship between the number of abnormal pressure information in multiple pressure information sets and multiple adjustment strategies, a target adjustment strategy is determined from the multiple adjustment strategies, including:

[0038] If the number of abnormal pressure information among multiple pressure information is less than a first number, a first adjustment strategy is selected as the target adjustment strategy to adjust the clamping force of each hydraulic cylinder on the tooling fixture based on the abnormal pressure information.

[0039] In response to the fact that the number of abnormal pressure information among multiple pressure information is greater than or equal to a first number and less than a second number, a second adjustment strategy is selected as the target adjustment strategy to adjust the clamping force of each hydraulic cylinder on the tooling fixture based on the proportion of the number of abnormal pressure information to the total number of pressure information.

[0040] If the number of abnormal pressure information among multiple pressure information is greater than or equal to the second number, a third adjustment strategy is selected as the target adjustment strategy to adjust the hydraulic cylinder clamping force of the hydraulic cylinder corresponding to the position of the abnormal pressure information on the tooling fixture.

[0041] The first quantity is less than the second quantity.

[0042] In one exemplary embodiment of this disclosure, determining a target adjustment strategy based on multiple pressure information includes:

[0043] A finite element pressure model of the tooling fixture is constructed based on multiple pressure information and the basic parameters of the tooling fixture.

[0044] Target adjustment strategies are determined based on finite element stress models.

[0045] In one exemplary embodiment of this disclosure, the data processing module includes a signal adjustment unit, a signal conversion unit, and a signal transmission unit.

[0046] The signal conversion unit is connected to both the signal adjustment unit and the signal transmission unit.

[0047] The signal adjustment unit is used to receive multiple pressure information sent by the multiple pressure sensors, amplify the multiple pressure information signals, and send the amplified multiple pressure information signals to the signal conversion unit.

[0048] The signal conversion unit is used to perform analog-to-digital conversion on multiple pressure information signals after signal amplification, and then send the multiple pressure information signals after analog-to-digital conversion to the signal transmission unit.

[0049] The signal transmission unit is used to send multiple pressure information after analog-to-digital conversion to the central control module.

[0050] The beneficial effects of the workpiece clamping force monitoring system provided in this disclosure are as follows: it can monitor the pressure information at different positions during the workpiece machining process in real time, ensuring the stability and safety of the workpiece during machining. Through information acquisition from multiple sensor modules, the data processing module can obtain pressure information at each position in real time, providing comprehensive data support for the central control module. Simultaneously, this disclosure embodiment has an intelligent adjustment function. The central control module can determine the optimal target adjustment strategy based on analysis and calculation of multiple pressure information. This intelligent adjustment method not only improves the control accuracy of clamping force but also significantly reduces manual maintenance costs and minimizes interference from human factors. Furthermore, different workpieces and machining requirements have different clamping force requirements. This disclosure embodiment can achieve precise control of the clamping force by adjusting the clamping force of the hydraulic cylinder at different positions according to actual needs, meeting the usage requirements in different scenarios. Attached Figure Description

[0051] To more clearly illustrate the technical solutions in the embodiments of this disclosure, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0052] Figure 1 This is a schematic diagram of the structure of a workpiece clamping force monitoring system for a fixture provided in an embodiment of this disclosure;

[0053] Figure 2 This is a schematic diagram of another workpiece clamping force monitoring system for a fixture provided in this embodiment of the present disclosure;

[0054] Figure 3 This is a circuit diagram of the data processing module provided in an embodiment of this disclosure;

[0055] Figure 4 This is a schematic diagram of the structure of another workpiece clamping force monitoring system for a fixture provided in this embodiment. Detailed Implementation

[0056] To enable those skilled in the art to better understand this solution, the technical solutions in the embodiments of this solution will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this solution, not all of them. Based on the embodiments of this solution, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this solution.

[0057] The term "comprising" and any other variations thereof in the specification, claims, and accompanying drawings of this invention mean "including but not limited to," and are intended to cover a non-exclusive inclusion, not limited to the examples listed herein. Furthermore, the terms "first" and "second," etc., are used to distinguish different objects, not to describe a specific order.

[0058] The implementation of this disclosure will be described in detail below with reference to the specific accompanying drawings:

[0059] This application adds pressure sensors to traditional tooling fixtures to achieve real-time monitoring of the clamping and cutting forces acting on the workpiece during machining. Each hydraulic cylinder on the fixture corresponds to one sensor, and the number of monitoring points varies depending on the sensor. The pressure sensors are positioned at the workpiece support location and can detect not only the clamping force but also the cutting force provided by the tool during forward and reverse machining. The pressure sensors have a range of up to 10KN and a small size (e.g., outer diameter 20mm, range 0-30KN). Some parts can be irregularly shaped. The sensors are connected by wires to transmit data to a data processing module and then to external devices via wireless communication technology. The wires can be embedded in pre-reserved wire grooves. The data processing module operates on a battery and displays the battery level. The data processing module can transmit data via wireless communication technology. The data processing module of this application is small in size, similar to a mobile phone, installed in a fixed position, and equipped with a transparent cover for waterproofing and dustproofing.

[0060] This application may also include external devices such as receivers, control cabinets, and displays. The display can show real-time pressure monitoring data, and the control cabinet can be set with pressure thresholds. When the monitored pressure data exceeds the pressure threshold, an alarm is triggered and the system shuts down, providing a protective function.

[0061] This application includes a recording function, allowing users to view pressure fluctuation curves on a monitor for easy troubleshooting in case of product issues. For example, pressure fluctuations may exceed a threshold without triggering an alarm or other abnormality. Data can be wirelessly transmitted to a mobile phone for remote monitoring via an app, allowing authorized personnel to adjust the hydraulic station pressure remotely. This combination of on-site and mobile adjustment provides greater convenience and flexibility for pressure control.

[0062] Figure 1 This is a schematic diagram of a workpiece clamping force monitoring system for a fixture, provided as an embodiment of this disclosure. (Refer to...) Figure 1 The workpiece clamping force monitoring system for the fixture includes multiple sensor modules 101, a data processing module 102, and a central control module 103.

[0063] Multiple sensor modules 101 are set at different positions on the tooling fixture, and the data processing module 102 is connected to the multiple sensor modules 101 and the central control module 103 respectively.

[0064] Multiple sensor modules 101 are used to collect multiple pressure information at corresponding locations and send the multiple pressure information to the data processing module 102.

[0065] The data processing module 102 is used to send multiple pressure information to the central control module 103.

[0066] The central control module 103 is used to determine the target adjustment strategy based on multiple pressure information, and adjust the clamping force of each hydraulic cylinder on the tooling fixture according to the target adjustment strategy.

[0067] In this embodiment, the tooling fixture includes a fixture plate for placing various workpieces. The fixture plate has wiring channels for accommodating the connection lines between the sensor module 101 and the data processing module 102. Fixtures are positioned at various locations on the workpieces. Each fixture consists of a hydraulic cylinder, a pressure plate, and pressure pins. The hydraulic cylinder is located at the rear end of the fixture, the pressure plate at the front end, and the pressure pins at the front end of the pressure plate, used to clamp the workpieces. Each hydraulic cylinder on the fixture corresponds to a pressure sensor, and the number of monitoring points for each pressure sensor varies depending on different requirements.

[0068] In this embodiment, multiple sensor modules 101 include pressure sensors, which are positioned at the workpiece support location. These pressure sensors can detect not only clamping force but also cutting force of the tool during forward and reverse machining of the workpiece. The multiple pressure sensors are respectively positioned at different locations on the tooling fixture to monitor and collect pressure information at corresponding locations in real time. These pressure sensors can collect pressure data and convert it into electrical signals.

[0069] For example, after the hydraulic cylinder applies a clamping force to the workpiece, the pressure sensor can monitor and output the current clamping force information in real time. This clamping force information reflects the tightness of the workpiece clamping. When machining a workpiece on a machine tool, the cutting tool applies a cutting force. The magnitude and direction of this cutting force vary depending on the machining method (front or back) and machining conditions. For instance, when machining from the front of the workpiece, the cutting force applied by the tool increases the force in the clamping direction, thus increasing the pressure value monitored by the sensor. Conversely, when machining from the back of the workpiece, the cutting force attempts to push the workpiece out of the fixture, resulting in a decrease in the pressure value monitored by the sensor. The combination of the generated cutting force and the clamping force provided by the hydraulic cylinder during workpiece cutting creates a stable, fluctuating pressure value change curve.

[0070] In this embodiment, the data processing module 102 is positioned at a predetermined location on the fixture plate and has a transparent cover for waterproofing and dustproofing. The data processing module 102 receives electrical signals from multiple sensor modules 101, converts them into processable data, and transmits the processed data to the central control module 103. In this embodiment, the central control module 103 receives pressure data from the data processing module 102 and determines a target adjustment strategy based on this data. For example, the central control module 103 can determine the pressure value that needs to be adjusted for each hydraulic cylinder and drive the cylinders to make corresponding adjustments via control signals.

[0071] For example, in the manufacturing process of automotive parts, tooling fixtures are used to fix and support workpieces for various processing operations. Multiple sensor modules 101 can be installed at key locations on the tooling fixture to monitor the pressure information on the workpiece in segments. When a sensor module 101 detects that the pressure at a certain location is lower or higher than a preset threshold, it can send this information to a data processing module 102. The data processing module 102 processes this information and sends it to a central control module 103. Based on the received pressure information, the central control module 103 determines the target position that needs adjustment and the corresponding adjustment strategy, and sends control signals to the hydraulic cylinders on the tooling fixture to adjust the clamping force of the corresponding cylinders, so that the workpiece achieves the optimal clamping state in the fixture.

[0072] This embodiment can monitor pressure information at different positions during workpiece processing in real time, ensuring the stability and safety of the workpiece during processing. Through information acquisition by multiple sensor modules 101, the data processing module 102 can obtain pressure information at various positions in real time, providing comprehensive data support for the central control module 103. Simultaneously, this embodiment features intelligent adjustment functionality. The central control module 103 can determine the optimal target adjustment strategy based on analysis and calculation of multiple pressure information. This intelligent adjustment method not only improves the control accuracy of clamping force but also significantly reduces manual maintenance costs and minimizes interference from human factors. Furthermore, different workpieces and processing requirements necessitate different clamping force requirements. This embodiment can achieve precise control of the clamping force by adjusting the hydraulic cylinder clamping force at different positions according to actual needs, meeting the usage requirements in different scenarios.

[0073] like Figure 2 As shown, in one embodiment of this disclosure, a workpiece clamping force monitoring system for a fixture further includes a first communication module 104 and a display module 105.

[0074] The first communication module 104 is connected to the data processing module 102 and the central control module 103 respectively, and the display module 105 is connected to the central control module 103.

[0075] The first communication module 104 is used to receive multiple pressure information sent by the data processing module 102 and forward the multiple pressure information to the central control module 103.

[0076] The central control module 103 is also used to send multiple pressure information to the display module 105 so that the display module 105 can display multiple pressure information.

[0077] In this embodiment, multiple sensor modules 101 distributed at different positions on the tooling fixture can collect pressure information at their respective positions in real time. This pressure information represents the clamping state of the workpiece in the fixture when no cutting is being performed, as well as the pressure data experienced by the workpiece during the cutting process. The sensor modules 101 can transmit the collected pressure information to the data processing module 102. The data processing module 102 can process and integrate this information. The processed data can be received by the first communication module 104 and forwarded to the central control module 103. The central control module 103 can receive the pressure information from the first communication module 104 and match the corresponding target adjustment strategy based on this information. At the same time, the central control module 103 can also send the received pressure information to the display module 105. The display module 105 can display this pressure information in an intuitive way, such as through numbers, charts, and graphs.

[0078] In this embodiment, the display module includes a monitor with a USB flash drive interface for connecting an external USB flash drive for data transfer. For example, when the module is operating, a USB flash drive can be plugged in, and measurement data can be recorded and stored every second, initially in the module's own memory. Newly recorded data is automatically transferred to the USB flash drive at 11:59 PM daily. The monitor also features status indicator lights: green indicates normal operation, red indicates sensor malfunction, and yellow indicates a malfunction in the corresponding acquisition channel. The displayed content can include pressure measurement data fluctuation curves, measurement status, menus, and time. The menus can include secondary menus such as digital calibration, physical calibration, and communication parameters, as well as a button to exit USB flash drive operation. Operators can use the display module to digitally calibrate sensor parameters and set communication parameters and system time.

[0079] For example, operators can monitor the clamping status of the fixture by viewing the pressure data fluctuation curve. The fluctuations provide a clear indication of any abnormal changes. For instance, if the fluctuation increases and the peak value increases during the time interval from T1 to T2, it indicates an abnormal increase in clamping force during this period. The causes could include excessive pressure adjustment in the hydraulic station system or machine tool collision. In such cases, operators can take emergency shutdown measures.

[0080] This embodiment improves the real-time performance and accuracy of data transmission between the data processing module 102 and the central control module 103, ensuring rapid transmission and adjustment of pressure information on the workpiece. It avoids untimely or erroneous adjustments due to data transmission delays or errors, thus guaranteeing the stability and precision of workpiece processing. Furthermore, operators can intuitively view the pressure information at various locations. This visual presentation not only enhances operational convenience but also allows operators to monitor the changing trends of the workpiece clamping state in real time, enabling them to identify and address problems more quickly.

[0081] like Figure 2 As shown, in one embodiment of this disclosure, a workpiece clamping force monitoring system for a fixture further includes a second communication module 106 and a first alarm module 107.

[0082] The central control module 103 is also connected to the second communication module 106 and the first alarm module 107 respectively. The second communication module 106 is used to connect to the external terminal 108.

[0083] The central control module 103 is also used to send a first alarm command to the first alarm module 107 when there is abnormal pressure information among multiple pressure information, so that the first alarm module 107 can issue an alarm.

[0084] The central control module 103 is also used to send multiple pressure information to the external terminal 108 via the second communication module 106, and to receive adjustment commands sent by the external terminal 108. The adjustment commands are used to instruct the adjustment of the clamping force of each hydraulic cylinder on the tooling fixture.

[0085] In this embodiment, the central control module 103 can receive pressure information from the data processing module 102 and analyze it in real time. When abnormal pressure information is detected, such as pressure exceeding a first threshold, the central control module 103 can send corresponding instruction information to the first alarm module 107 based on this information. After receiving the instruction, the first alarm module 107 can trigger audible and visual alarms and information alarms, sending corresponding alarm signals to the operator.

[0086] For example, after the hydraulic cylinder provides clamping force to the workpiece, the pressure sensor can monitor the pressure changes on the workpiece in real time and transmit the pressure information to the data processing module 102. At this time, the workpiece is only subjected to clamping force. The data processing module 102 processes the pressure information and transmits it to the central control module 103. When the clamping force does not reach the preset minimum threshold in the unprocessed state, the first alarm module 107 can issue a low-pressure alarm, and the central control module 103 can generate an instruction to increase the clamping force. When the clamping force exceeds the preset maximum threshold in the unprocessed state, the first alarm module 107 can issue an overpressure alarm, and the central control module 103 can generate an instruction to reduce the clamping force.

[0087] For example, when a workpiece is being machined, the cutting tool applies a cutting force to the workpiece. At this time, the workpiece is subjected to clamping force and cutting force. The cutting force causes changes in the pressure on the workpiece, and these changes are monitored in real time by a pressure sensor and transmitted to the data processing module 102. The data processing module 102 processes the pressure information and transmits it to the central control module 103. The central control module plots the pressure fluctuation curve based on this data and transmits it to the display module 105. When the pressure on the workpiece exceeds a preset high-pressure alarm threshold during cutting, the first alarm module 107 can immediately issue a high-pressure alarm signal. The high-pressure alarm signal can include audible and visual alarms and information alarms. The information alarm can include cause analysis, such as excessive pressure adjustment in the hydraulic station system or machine tool collision. After receiving the alarm signal, the operator can pause machining, check for abnormalities in the cutting tool, fixture, or workpiece, and take appropriate measures. For example, the cutting parameters can be adjusted, the cutting tool replaced, or the workpiece re-clamped. When the pressure on the workpiece during the cutting process is lower than the preset low-pressure alarm threshold, the first alarm module 107 can issue a low-pressure alarm signal. The low-pressure alarm signal can include audible and visual alarms and information alarms. The information alarm can include cause analysis, such as damage to the hydraulic station valve block, pump or cylinder, resulting in oil leakage from the cylinder, internal cavity leakage or fixture leakage.

[0088] For example, the central control module 103 can send real-time pressure information to an external terminal 108, such as a mobile phone or computer, via the second communication module 106. The external terminal 108 can send adjustment commands to the central control module 103 to remotely adjust the clamping force of each hydraulic cylinder on the tooling fixture. After receiving the adjustment command from the external terminal 108, the central control module 103 can send control signals to the corresponding hydraulic cylinder according to the command content to adjust the clamping force of the hydraulic cylinder.

[0089] This embodiment enables real-time communication with an external terminal 108, allowing operators to remotely monitor the workpiece clamping status and send adjustment commands to adjust the hydraulic cylinder clamping force as needed. This remote monitoring and adjustment function not only improves work efficiency but also reduces the operator's workload. Furthermore, it can immediately issue alarms for any abnormalities during operation, reminding operators to take timely measures to prevent workpiece damage or decreased machining accuracy caused by abnormal clamping force.

[0090] like Figure 2 As shown in one embodiment of this disclosure, a workpiece clamping force monitoring system for a fixture further includes a second alarm module 108. The second alarm module 108 is connected to the data processing module 102 and the central control module 103, respectively.

[0091] The data processing module 102 is also used to generate a second alarm command based on multiple pressure information and send the second alarm command to the second alarm module 108 so that the second alarm module 108 can issue an alarm.

[0092] The data processing module 102 is also used to generate a second alarm command based on multiple pressure information and send the second alarm command to the central control module 103.

[0093] In this embodiment, the data processing module 102 is further configured to generate a second alarm command based on multiple pressure information. The data processing module 102 can generate different alarm commands according to the proportion of abnormal information in the pressure information.

[0094] For example, pressure information is collected from 12 monitoring points. The data processing module 102 can generate different alarm commands based on the proportion of abnormal information in these 12 pressure information points. Abnormal information is information that exceeds a preset threshold. For example, when the number of abnormal information points is 0, no alarm is triggered. When the number of abnormal information points is greater than 0 and less than 3, a first alarm command is generated. When the number of abnormal information points is greater than 3 and less than 6, a second alarm command is generated. When the number of abnormal information points is greater than 6, a third alarm command is generated.

[0095] This embodiment can identify different degrees of clamping force abnormalities by setting different alarm thresholds, thereby avoiding false alarms or missed alarms that may be caused by a single threshold limitation. Different levels of alarm commands provide operators with clearer and more timely alarm information, helping them to take different measures in a timely manner.

[0096] like Figure 2 As shown, in one embodiment of this disclosure, the data processing module 102 includes a signal processing unit 109 and a comparison unit 110.

[0097] The signal processing unit 109 is used to convert multiple pressure information into multiple pressure signals respectively, and send the multiple pressure signals to the comparison unit 110.

[0098] The comparison unit 110 is used to compare multiple pressure signals and multiple standard pressure signals one by one, generate a second alarm command based on the comparison result, and send the second alarm command to the second alarm module 108.

[0099] In this embodiment, the signal processing unit 109 can amplify, filter, and denoise the received signals, and the comparison unit 110 compares these processed signals with preset standard signals one by one. The standard signals are set according to the workpiece processing requirements and fixture design parameters, representing the pressure range that the fixture should provide during normal operation. The comparison unit 110 can compare whether each signal exceeds the upper and lower limits of the standard signal, thereby determining whether the clamping force is normal.

[0100] For example, when the comparison unit 110 detects that a signal exceeds the upper or lower limit of the standard signal, i.e., an anomaly exists, it can generate a second alarm command of different levels based on the number and severity of the abnormal signal. The alarm command level can be set according to actual needs, such as minor anomaly, moderate anomaly, and severe anomaly.

[0101] This embodiment can improve the accuracy and reliability of monitoring. By generating a second alarm command, operators can quickly learn about the abnormal state of the clamping force and take timely measures to ensure the safety and stability of workpiece processing.

[0102] like Figure 3 As shown, in one embodiment of this disclosure, the comparison unit 110 includes a first comparison subunit and a second comparison subunit.

[0103] The first comparator subunit includes amplifier U1, amplifier U2, OR gate H1, transistor Q1, and power supply VCC.

[0104] Amplifier U1 has its non-inverting input connected to the signal processing unit, its inverting input used to receive the reference voltage V1, and its output connected to the first input of OR gate H1.

[0105] Amplifier U2 has its non-inverting input connected to the non-inverting input of amplifier U1, its inverting input used to receive the reference voltage V2, and its output connected to the second input of OR gate H1.

[0106] The output of OR gate H1 is connected to the base of transistor Q1.

[0107] Transistor Q1 has its collector connected to the power supply VCC and its emitter connected to the alarm.

[0108] The second comparator unit includes amplifier U3, amplifier U4, OR gate H2, transistor Q2, and power supply VCC.

[0109] Amplifier U3 has its non-inverting input connected to the signal processing unit, its inverting input used to receive the reference voltage V3, and its output connected to the first input of OR gate H2.

[0110] Amplifier U4 has its non-inverting input connected to the non-inverting input of amplifier U3, its inverting input used to receive the reference voltage V4, and its output connected to the second input of OR gate H2.

[0111] The output of OR gate H2 is connected to the base of transistor Q2.

[0112] Transistor Q2 has its collector connected to the power supply VCC and its emitter connected to the alarm.

[0113] For example, in the first comparison subunit, amplifiers U1 and U2 simultaneously receive pressure signals from signal processing unit 109 and compare these signals with preset reference voltages V1 and V2. Reference voltages V1 and V2 are preset and represent the upper and lower limits of the normal range of clamping force. When the pressure signal is lower than the reference voltage V1, amplifier U1 outputs a low level, indicating that the clamping force is too small. When the pressure signal is higher than the reference voltage V2, amplifier U2 outputs a high level, indicating that the clamping force is too large. If the pressure signal is between V1 and V2, both amplifiers output a low level, indicating that the clamping force is normal. OR gate H1 receives the output signals from amplifiers U1 and U2. When either amplifier outputs a high level (i.e., an abnormality exists), OR gate H1 outputs a high-level signal. This high-level signal can drive transistor Q1 to conduct, thereby allowing the alarm to receive current from the power supply VCC and triggering the alarm.

[0114] In this embodiment, the comparison unit 110 further includes multiple comparison sub-units, such as a third comparison sub-unit, a fourth comparison sub-unit, and so on up to the Nth comparison sub-unit. These multiple comparison sub-units have identical structures and are connected in parallel. All multiple comparison sub-units are connected to an alarm. When the pressure signal is abnormal, the corresponding comparison sub-unit circuit is activated. As the number of abnormal signals increases, the number of activated comparison sub-units increases, thus increasing the current across the alarm and strengthening the alarm sound.

[0115] In this embodiment, the alarm includes a resistor R1, a transistor Q4, a buzzer BUZ1, a power supply VDD, a capacitor C1, and a resistor R2. The base of transistor Q4 is connected to the first end of resistor R1, the collector is connected to the first end of the buzzer, and the emitter is connected to the first end of resistor R2 and the central control module 103. The second end of the buzzer is connected to the power supply VDD. The second end of resistor R1 is connected to the comparator unit 110. The first end of the capacitor is connected to the first end of resistor R2, the second end of the capacitor is connected to the second end of resistor R2, and the second end of resistor R2 is grounded. The RC circuit composed of capacitor C1 and resistor R2 is used to stabilize the operating state of transistor Q4 and prevent damage to the circuit due to sudden current changes.

[0116] For example, when the pressure information exceeds a preset threshold, the comparison unit 110 can output a high-level signal to the second terminal of resistor R1. This high-level signal is transmitted to the base of transistor Q4 through resistor R1, causing Q4 to conduct. When Q4 conducts, a path is formed between its collector and the power supply VDD, and the first terminal of buzzer BUZ1 receives current from VDD through the collector of Q4, thereby triggering the buzzer to emit an alarm sound. The emitter of Q4 is connected to the central control module 103 through resistor R2. The central control module 103 can receive the alarm signal, perform calculations and analysis, and determine the urgency of the abnormal situation. Then, corresponding control measures are taken, such as sending the alarm information to the display module 105 for storage.

[0117] This embodiment can classify abnormal situations and issue different alarm messages to assist operators in taking more precise countermeasures and improve the efficiency of abnormal handling.

[0118] In one embodiment of this disclosure, a target adjustment strategy is determined based on multiple pressure information, including:

[0119] Based on the matching relationship between the number of abnormal pressure information in multiple pressure information and multiple adjustment strategies, the target adjustment strategy is determined from multiple adjustment strategies.

[0120] In this embodiment, the data processing module 102 can analyze the received pressure information in real time to detect whether there is abnormal pressure information, that is, whether there is a value that exceeds or falls below the preset normal pressure range. The central control module 103 can receive this abnormal pressure information and, based on the matching relationship between the number of abnormal pressure information and multiple preset adjustment strategies, automatically select the most suitable target adjustment strategy from multiple adjustment strategies.

[0121] For example, a fixture on an automotive production line has a normal clamping force range greater than x Newtons and less than y Newtons, based on the actual processing requirements of the workpiece. Sensor module 101 collects m pressure information points, among which two pressure information points are below x Newtons and above y Newtons, respectively, and are considered abnormal pressure information. Central control module 103 can match these two abnormal pressure information points with multiple preset adjustment strategies based on their quantity and type. For example, strategy A is suitable for a single, minor abnormality, while strategy B is suitable for multiple or more severe abnormalities; in this case, the system will select strategy B as the target adjustment strategy. After determining the target adjustment strategy, central control module 103 can control the hydraulic cylinder to automatically adjust the clamping force of the fixture, restoring it to the normal range.

[0122] This embodiment can intelligently select the most suitable adjustment strategy based on the matching of the number of abnormal information and the adjustment strategy, thereby ensuring precise control of the clamping force of the fixture, improving production efficiency and product quality, and reducing manual maintenance costs and repair risks.

[0123] In one embodiment of this disclosure, the multiple adjustment strategies include a first adjustment strategy, a second adjustment strategy, and a third adjustment strategy.

[0124] Based on the matching relationship between the number of abnormal pressure information in multiple pressure information sets and multiple adjustment strategies, a target adjustment strategy is determined from the multiple adjustment strategies, including:

[0125] If the number of abnormal pressure information among multiple pressure information is less than a first number, a first adjustment strategy is selected as the target adjustment strategy to adjust the clamping force of each hydraulic cylinder on the tooling fixture based on the abnormal pressure information.

[0126] In response to the fact that the number of abnormal pressure information among multiple pressure information is greater than or equal to a first number and less than a second number, a second adjustment strategy is selected as the target adjustment strategy to adjust the clamping force of each hydraulic cylinder on the tooling fixture based on the proportion of the number of abnormal pressure information to the total number of pressure information.

[0127] If the number of abnormal pressure information among multiple pressure information is greater than or equal to the second number, a third adjustment strategy is selected as the target adjustment strategy to adjust the hydraulic cylinder clamping force of the hydraulic cylinder corresponding to the position of the abnormal pressure information on the tooling fixture.

[0128] The first quantity is less than the second quantity.

[0129] In this embodiment, the data processing module 102 can analyze multiple received pressure information to detect whether there is any abnormal pressure information. When abnormal pressure information is detected, the central control module 103 can compare the number of abnormal pressure information with a preset first number and a preset second number, thereby selecting an appropriate adjustment strategy.

[0130] For example, when the number of abnormal pressure information is less than a first quantity, the degree of abnormality is judged to be low, and the first adjustment strategy is selected. The first adjustment strategy includes uniformly adjusting the clamping force of all cylinders on the tooling fixture with low precision based on the abnormal pressure information, such as uniformly increasing or decreasing 'a' Newtons, so that the force gradually returns to the normal range.

[0131] If the number of abnormal pressure signals falls between the first and second highest levels, the degree of abnormality is considered high, and a second adjustment strategy is selected. This strategy involves dynamically adjusting the cylinder clamping force based on the proportion of abnormal pressure signals to all pressure signals, in order to correct the abnormality more quickly.

[0132] When the number of abnormal pressure signals reaches or exceeds the second threshold, a serious anomaly is identified, and a third adjustment strategy is selected. This third adjustment strategy involves high-precision, targeted adjustments to the cylinders corresponding to the locations of the abnormal pressure signals, ensuring that the clamping force in these areas can quickly return to normal.

[0133] For example, in a fixture system of a metal processing plant, the preset first quantity is 2, and the preset second quantity is 5. The central control module 103 detects 3 abnormal pressure readings out of 10 pressure readings. Since the number of abnormal readings is greater than the first quantity but less than the second quantity, a second adjustment strategy is activated. The proportion of abnormal pressure readings to the total readings is calculated, for example, 30%. Based on this proportion, the hydraulic pressure of all cylinders on the fixture is adjusted proportionally, for example, with an adjustment precision set to 10, uniformly increasing or decreasing by 10b Newtons. When the proportion is 40%, the adjustment precision is increased accordingly, with the adjustment unit set to 5, uniformly increasing or decreasing by 5b Newtons.

[0134] This embodiment can flexibly classify the pressure based on the quantity of different abnormal pressure information and adjust the clamping force of the tooling fixture's hydraulic cylinder according to different adjustment strategies, thereby achieving precise and efficient clamping force control. The graded adjustment strategy not only improves the system's intelligence level and avoids unnecessary over-intervention, but also greatly enhances the stability and reliability of production.

[0135] In one embodiment of this disclosure, a target adjustment strategy is determined based on multiple pressure information, including:

[0136] A finite element pressure model of the tooling fixture is constructed based on multiple pressure information and the basic parameters of the tooling fixture.

[0137] Target adjustment strategies are determined based on finite element stress models.

[0138] In this embodiment, the finite element pressure model can simulate the pressure distribution and changes in various areas of the fixture during actual operation, and pressure adjustment data can be obtained by analyzing and calculating based on the model.

[0139] For example, pressure information at various locations during workpiece machining, as well as basic fixture parameters such as dimensions, material, and structure, are acquired. Based on this data and parameters, a three-dimensional finite element pressure model is constructed using finite element analysis (FEM) technology to simulate the deformation and stress distribution of the fixture in various regions under external forces. FEM is a method that transforms complex physical problems into mathematical models for solution; it can simulate the deformation, stress, and pressure distribution of a fixture under external forces. By performing simulation analysis on the finite element pressure model, potential pressure anomaly regions are identified. Based on the specific conditions of these anomaly regions, appropriate target adjustment strategies are determined. These strategies may include adjusting the hydraulic cylinder clamping force in a certain region, changing the clamping method of the fixture, or optimizing the fixture structure.

[0140] This embodiment can accurately simulate the pressure distribution and changes of the workpiece in actual work, enabling the system to detect potential abnormal pressure areas in a timely manner, and to address the problem of uneven or unstable clamping force of the fixture in a targeted manner, thereby improving the working performance of the fixture and the machining accuracy of the workpiece.

[0141] like Figure 4 As shown, in one embodiment of this disclosure, the data processing module 102 includes a signal adjustment unit 111, a signal conversion unit 112, and a signal transmission unit 113.

[0142] The signal conversion unit 112 is connected to the signal adjustment unit 111 and the signal transmission unit 113 respectively.

[0143] The signal adjustment unit 111 is used to receive multiple pressure information sent by multiple pressure sensors, amplify the multiple pressure information signals, and send the amplified multiple pressure information signals to the signal conversion unit 112.

[0144] The signal conversion unit 112 is used to perform analog-to-digital conversion on multiple pressure information after signal amplification, and send the multiple pressure information after analog-to-digital conversion to the signal transmission unit 113.

[0145] The signal transmission unit 113 is used to send multiple pressure information after analog-to-digital conversion to the central control module 103.

[0146] In this embodiment, the signal adjustment unit 111 can receive raw pressure information from multiple pressure sensors. Since these sensors are located at different positions on the fixture, and their working environments and conditions vary, the received signals may differ and experience interference. The signal adjustment unit 111 amplifies these signals to ensure signal strength and stability. The amplified pressure signal is sent to the signal conversion unit 112. The signal conversion unit 112 converts the analog signal into a digital signal, i.e., performs analog-to-digital conversion (A / D conversion). The digital signal after A / D conversion is sent to the signal transmission unit 113. The signal transmission unit 113 further processes these digital signals, such as filtering, smoothing, and calculation, to eliminate noise and interference and improve signal accuracy. The processed pressure information is then sent to the central control module 103.

[0147] This embodiment can improve the stability and reliability of the signal, eliminate noise and interference, and make the pressure information finally sent to the central control module 103 more accurate and reliable.

[0148] The above embodiments are only used to illustrate the technical solutions of this disclosure, and are not intended to limit it. Although this disclosure has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this disclosure.

Claims

1. A workpiece clamping force monitoring system for a fixture, characterized in that, include: Multiple sensor modules, data processing modules, and central control modules; The multiple sensor modules are set at different positions on the tooling fixture, and the data processing module is connected to the multiple sensor modules and the central control module respectively. The multiple sensor modules are used to collect multiple pressure information at corresponding locations and send the multiple pressure information to the data processing module; The data processing module is used to send the multiple pressure information to the central control module; The central control module is used to determine the target adjustment strategy based on the multiple pressure information, and adjust the hydraulic cylinder clamping force of each hydraulic cylinder on the tooling fixture according to the target adjustment strategy; The determination of the target adjustment strategy based on the multiple pressure information includes: In response to the fact that the number of abnormal pressure information among the plurality of pressure information is less than a first number, a first adjustment strategy is selected as the target adjustment strategy to adjust the hydraulic cylinder clamping force of each hydraulic cylinder on the tooling fixture based on the abnormal pressure information. In response to the fact that the number of abnormal pressure information among the plurality of pressure information is greater than or equal to a first number and less than a second number, a second adjustment strategy is selected as the target adjustment strategy to adjust the hydraulic cylinder clamping force of each hydraulic cylinder on the tooling fixture based on the proportion of the number of abnormal pressure information to the total number of pressure information. In response to the fact that the number of abnormal pressure information among the plurality of pressure information is greater than or equal to the second number, a third adjustment strategy is selected as the target adjustment strategy to adjust the hydraulic cylinder clamping force of the hydraulic cylinder corresponding to the position of the abnormal pressure information on the tooling fixture; the first number is less than the second number.

2. The workpiece clamping force monitoring system for a fixture as described in claim 1, characterized in that, It also includes a first communication module and a display module; The first communication module is connected to both the data processing module and the central control module, and the display module is connected to the central control module. The first communication module is used to receive the plurality of pressure information sent by the data processing module and forward the plurality of pressure information to the central control module; The central control module is also used to send the multiple pressure information to the display module so that the display module can display the multiple pressure information.

3. The workpiece clamping force monitoring system for a fixture as described in claim 1, characterized in that, It also includes a second communication module and a first alarm module; The central control module is also connected to the second communication module and the first alarm module respectively, and the second communication module is used to connect to an external terminal. The central control module is also used to send a first alarm command to the first alarm module when there is abnormal pressure information among the multiple pressure information, so that the first alarm module can issue an alarm. The central control module is also used to send the multiple pressure information to the external terminal through the second communication module, and to receive adjustment instructions sent by the external terminal; the adjustment instructions are used to instruct the adjustment of the hydraulic cylinder clamping force of each hydraulic cylinder on the tooling fixture.

4. The workpiece clamping force monitoring system for a fixture as described in claim 1, characterized in that, It also includes a second alarm module; the second alarm module is connected to the data processing module and the central control module respectively; The data processing module is also used to generate a second alarm command based on the plurality of pressure information, and send the second alarm command to the second alarm module so that the second alarm module can issue an alarm; The data processing module is also used to generate a second alarm command based on the multiple pressure information, and send the second alarm command to the central control module.

5. The workpiece clamping force monitoring system for a fixture as described in claim 4, characterized in that, The data processing module includes a signal processing unit and a comparison unit; The signal processing unit is used to convert the plurality of pressure information into a plurality of pressure signals respectively, and send the plurality of pressure signals to the comparison unit; The comparison unit is used to compare the plurality of pressure signals and the plurality of standard pressure signals one by one, generate a second alarm command based on the comparison result, and send the second alarm command to the second alarm module.

6. The workpiece clamping force monitoring system for a fixture as described in claim 5, characterized in that, The comparison unit includes a first comparison subunit and a second comparison subunit; The first comparison subunit includes: amplifier U1, amplifier U2, OR gate H1, transistor Q1 and power supply VCC; The amplifier U1 has its non-inverting input terminal connected to the signal processing unit, its inverting input terminal used to receive the reference voltage V1, and its output terminal connected to the first input terminal of the OR gate H1. The amplifier U2 has its non-inverting input connected to the non-inverting input of the amplifier U1, its inverting input used to receive the reference voltage V2, and its output connected to the second input of the OR gate H1. The output terminal of the OR gate H1 is connected to the base of the transistor Q1; The collector of the transistor Q1 is connected to the power supply VCC, and the emitter is connected to the alarm. The second comparator subunit includes: amplifier U3, amplifier U4, OR gate H2, transistor Q2, and power supply VCC; The amplifier U3 has its non-inverting input terminal connected to the signal processing unit, its inverting input terminal used to receive the reference voltage V3, and its output terminal connected to the first input terminal of the OR gate H2. The amplifier U4 has its non-inverting input connected to the non-inverting input of the amplifier U3, its inverting input used to receive the reference voltage V4, and its output connected to the second input of the OR gate H2. The output terminal of the OR gate H2 is connected to the base of the transistor Q2; The collector of the transistor Q2 is connected to the power supply VCC, and the emitter is connected to the alarm.

7. The workpiece clamping force monitoring system for a fixture as described in claim 1, characterized in that, The data processing module includes a signal adjustment unit, a signal conversion unit, and a signal transmission unit; The signal conversion unit is connected to both the signal adjustment unit and the signal transmission unit. The signal adjustment unit is used to receive multiple pressure information sent by the multiple sensor modules, amplify the multiple pressure information, and send the amplified multiple pressure information to the signal conversion unit; The signal conversion unit is used to perform analog-to-digital conversion on multiple pressure information signals after signal amplification, and send the multiple pressure information signals after analog-to-digital conversion to the signal transmission unit; The signal transmission unit is used to send multiple pressure information after analog-to-digital conversion to the central control module.

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