A reliability test device and test method for a replaceable broach mechanism

Abstract

The present invention proposes a replaceable broaching mechanism reliability test device and test method to solve the limitation that the current electric spindle reliability test device cannot perform reliability tests on key components. The electric spindle is connected and fixed to the electric spindle clamping mechanism of the electric spindle support module; the replaceable simulated tool holder module is connected and fixed to the internal broaching mechanism of the electric spindle through the replaceable tool holder upper part; the working platform base of the performance detection module and the ground iron of the electric spindle support module are connected and fixed by bolts; the tool holder feeding module is installed on the working platform base of the performance detection module, and the tool holder auxiliary feeding mechanism cooperates with the groove of the lower part of the replaceable tool holder. Using this test device, according to the model of the machine tool spindle or the test spindle, the corresponding replaceable tool holder upper part and the replaceable tool holder lower part are selected for assembly, and then functional tests, performance detection tests and fault diagnosis tests are carried out.

Description

Technical Field

[0001] The invention belongs to the technical field of machine tool functional component testing equipment, and in particular relates to a replaceable broach mechanism reliability testing device and a testing method. Background Art

[0002] As a key component of the electric spindle, the broaching mechanism can automatically tighten and loosen the tool inside the electric spindle. Its performance and reliability have a great impact on the operation status of the electric spindle and even the machine tool, as well as the workpiece processing accuracy. Traditional electric spindle reliability test devices generally focus on simulating the real working condition loading and performance detection of the electric spindle as a whole, and cannot perform reliability tests on key components of the electric spindle. Designing a reliability test device for the broaching mechanism to realize the automatic pushing of the tool handle, conduct functional tests, performance test tests, and fault diagnosis tests, can provide a data basis for the reliability study of the broaching mechanism. Designing a replaceable simulated tool handle with threaded connection can simultaneously meet the needs of different types of electric spindles in field tests and bench tests, and realize the replaceability, portability, universality and functional diversity of the reliability device. The reliability study of the broaching mechanism can be carried out through the data such as the number of tool changes and tool change time recorded in the functional test, and the relationship between the fault of the broaching mechanism and various performance parameters can be analyzed through performance test tests and fault diagnosis tests. Summary of the invention

[0003] In order to solve the limitation that reliability tests cannot be performed on key components of an electric spindle, the present invention proposes a replaceable broach mechanism reliability test device and test method.

[0004] The technical solution adopted by the present invention is:

[0005] The replaceable broaching mechanism reliability testing device comprises five modules: an electric spindle, an electric spindle support module, a replaceable simulated tool holder module, a performance detection module, and a tool holder feeding module; the electric spindle is connected and fixed to the electric spindle clamping mechanism of the electric spindle support module; the replaceable simulated tool holder module is connected and fixed to the broaching mechanism inside the electric spindle through the upper part of the replaceable tool holder; the working platform base of the performance detection module and the ground iron of the electric spindle support module are fixed by bolts; the tool holder feeding module is installed on the working platform base of the performance detection module, and the tool holder auxiliary feeding mechanism cooperates with the groove at the lower part of the replaceable tool holder.

[0006] The electric spindle support module includes an electric spindle clamping mechanism, an electric spindle support column, and a ground iron; the electric spindle clamping mechanism is fixed to the electric spindle support column by bolts; the electric spindle support column is fixed to the ground iron by bolts.

[0007] The replaceable simulated tool holder module includes a replaceable tool holder upper part, a replaceable tool holder lower part, a loading bearing, and a bearing sleeve; the replaceable tool holder upper part includes a BT tool holder and an HSK tool holder, and the replaceable tool holder upper part is connected to the replaceable tool holder lower part by a thread; the loading bearing is installed on the replaceable tool holder lower part by an interference fit; the bearing sleeve is installed on the loading bearing by an interference fit, so as to realize the dynamic loading of the electric spindle by the radial force loading device.

[0008] The performance detection module includes a sensor module, a radial force loading module, an integrated working platform, a working platform bracket, and a working platform base; the sensor module is fixed to the integrated working platform by bolts; the radial force loading module is fixed to the integrated working platform by bolts; the integrated working platform is connected to the top of the two working platform brackets by bolts; the bottom of the two working platform brackets is fixed to the working platform base by bolts.

[0009] The sensor module includes a laser displacement sensor I, a laser displacement sensor II, a laser displacement sensor III, a sensor guide frame, and a sensor bracket; the laser displacement sensor I, the laser displacement sensor II, and the laser displacement sensor III are fixedly connected to the sensor guide frame by bolts, so as to adjust the sensor position and perform performance testing on the test object; the sensor guide frame and the sensor bracket are fixedly connected by bolts. The radial force loading module includes a radial force loading device, a radial force loading device clamp, and a radial force loading device bracket; the radial force loading device is connected and fixedly connected to the radial force loading device clamp; the radial force loading device clamp is fixedly connected to the top of the radial force loading device bracket by bolts.

[0010] The tool holder feeding module comprises a tool holder auxiliary feeding mechanism, a feeding cylinder, a cylinder connecting plate, and an electric turntable; the tool holder auxiliary feeding mechanism is connected to the feeding cylinder via threads; the feeding cylinder is fixed to the cylinder connecting plate and the electric turntable via bolts.

[0011] The present invention also proposes a reliability test method using the replaceable broaching mechanism reliability test device as described above, comprising the following steps: selecting the corresponding replaceable tool holder upper part and replaceable tool holder lower part for assembly according to the model of the machine tool spindle or the test spindle; matching the groove of the replaceable tool holder lower part after assembly with the tool holder auxiliary feeding mechanism to achieve self-locking of the two and pushing the replaceable simulated tool holder module to the inner conical surface of the electric spindle; performing a functional test on the broaching mechanism, and recording the number of tool changes, tool change time, etc. to provide a data basis for reliability analysis; performing a performance detection test on the broaching mechanism to obtain performance parameters such as the dynamic and static stiffness of the spindle and tool holder joint surface, the broaching force, etc., and use them as a criterion for static and dynamic analysis and fault diagnosis of the electric spindle; performing a fault diagnosis test on the broaching mechanism, and diagnosing the fault of the broaching mechanism based on the obtained performance detection results and the transient vibration of the broaching process.

[0012] In one embodiment of the present invention, when conducting a functional test of the broaching mechanism, it specifically includes: the feed cylinder carries the tool holder auxiliary feed mechanism to push the replaceable simulated tool holder module upward from the initial position to the inner conical surface of the electric spindle; the internal broaching mechanism of the electric spindle performs broaching, so that the inner conical surface of the electric spindle is tightly combined with the outer conical surface of the upper part of the replaceable tool holder; the electric turntable rotates a certain angle, the lower part of the replaceable tool holder and the tool holder auxiliary feed mechanism are released from self-locking, and the feed cylinder carries the tool holder auxiliary feed mechanism downward to the initial position; the frequency converter controlling the electric spindle is turned on to control the electric spindle to rotate with the tool at a certain speed, and the radial force loading device is aligned with the The groove of the bearing sleeve is contacted and the running electric spindle is dynamically loaded to realize the simulation of the real working condition; the electric spindle runs with the tool for a period of time, the radial force loading device is unloaded, and the operation of the electric spindle is stopped; the feed cylinder carries the tool holder auxiliary feed mechanism from the initial position to the inside of the groove at the lower part of the replaceable tool holder, the electric turntable rotates in the opposite direction by a certain angle, and the lower part of the replaceable tool holder and the tool holder auxiliary feed mechanism are self-locked; the feed cylinder carries the tool holder auxiliary feed mechanism and the replaceable simulated tool holder module down to the initial position; repeat the above steps, and record the number of tool changes, tool change time, electric spindle with tool operation time, electric spindle with tool loading time, etc.

[0013] In one embodiment of the present invention, when performing a broaching mechanism performance test, it specifically includes: after performing a functional test, tightening the broaching detection device through the broaching mechanism inside the electric spindle to obtain the broaching force; adjusting the position of the laser displacement sensor II on the sensor guide frame, and making the test direction of the laser displacement sensor II and the force loading direction of the radial force loading device in a straight line; contacting the radial force loading device with the groove of the bearing sleeve, applying different radial forces to obtain static stiffness; turning on the frequency converter that controls the electric spindle, and controlling the electric spindle to rotate with the tool at a certain speed; contacting the radial force loading device with the groove of the bearing sleeve, applying different radial forces to obtain dynamic stiffness; adjusting the positions of the laser displacement sensor I and the laser displacement sensor III on the sensor guide frame, and making the test directions of the laser displacement sensor I and the laser displacement sensor III at 90° to obtain rotation accuracy.

[0014] In one embodiment of the present invention, when performing a fault diagnosis test on the broaching mechanism, it specifically includes: adsorbing the vibration sensor to the end of the electric spindle through magnetic force, and installing the cylinder pressure sensor on the tool-beating cylinder of the electric spindle; performing a single functional test of the broaching mechanism to obtain the transient vibration values ​​of the broaching and loosening and the tool-beating cylinder pressure values.

[0015] Beneficial effects of the invention: The invention discloses a replaceable broaching mechanism reliability test device, which can be used to perform reliability tests on key components of electric spindles, solving the limitations in the reliability test of the electric spindle as a whole. A replaceable simulated tool holder with a threaded connection is designed to meet the needs of different types of electric spindles, so as to achieve the replaceability, universality, and functional diversity of the test device, and reduce the cost of manufacturing the simulated tool holder. The test device described in the invention can realize functional tests, performance detection tests, and fault diagnosis tests on the broaching mechanism, and study the reliability of the broaching mechanism based on the test data. Designing a reliability test device for the broaching mechanism and conducting reliability tests on the broaching mechanism have important guiding significance for studying the reliability of the electric spindle. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 The figure shows a schematic structural diagram of a replaceable broach mechanism reliability test device according to the present invention;

[0017] Figure 2 Shown is a schematic structural diagram of the electric spindle support module of the present invention;

[0018] Figure 3 The figure shows a schematic structural diagram of a replaceable simulated tool handle module according to the present invention;

[0019] Figure 4The figure shows a cross-sectional view of the assembly of the BT type replaceable knife handle upper part and the replaceable knife handle lower part according to the present invention;

[0020] Figure 5 The figure shows a cross-sectional view of the assembly of the upper part of the HSK type replaceable tool handle and the lower part of the replaceable tool handle according to the present invention;

[0021] Figure 6 FIG. 2 is a schematic diagram showing the structure of the performance detection module according to the present invention;

[0022] Figure 7 Shown is a schematic structural diagram of the tool holder feeding module of the present invention.

[0023] In the figure:

[0024] 1 electric spindle, 2 electric spindle support module, 2-1 electric spindle clamping mechanism, 2-2 electric spindle support column, 2-3 ground iron, 3 replaceable simulated tool holder module, 3-1 replaceable tool holder upper part, 3-2 replaceable tool holder lower part, 3-3 loading bearing, 3-4 bearing sleeve, 4 performance detection module, 4-1 sensor module, 4-1-1 laser displacement sensor I, 4-1-2 laser displacement sensor II, 4-1-3 laser displacement sensor III, 4-1-4 sensor guide frame, 4-1-5 sensor bracket, 4-2 radial force loading module, 4-2-1 radial force loading device, 4-2-2 radial force loading device clamp, 4-2-3 radial force loading device bracket, 4-3 integrated working platform, 4-4 working platform bracket, 4-5 working platform base, 5 tool holder feeding module, 5-1 tool holder auxiliary feeding mechanism, 5-2 feeding cylinder, 5-3 cylinder connecting plate, 5-4 electric turntable. DETAILED DESCRIPTION

[0025] Specific implementation method 1: Combination Figure 1 to Figure 7 This embodiment provides a specific implementation scheme of a replaceable broaching mechanism reliability test device. The replaceable broaching mechanism reliability test device comprises five modules: an electric spindle 1, an electric spindle support module 2, a replaceable simulated tool handle module 3, a performance detection module 4, and a tool handle feed module 5. Figure 1 The electric spindle 1 is connected and fixed to the electric spindle clamping mechanism 2-1 of the electric spindle support module 2, the replaceable simulated tool holder module 3 is connected and fixed to the internal broaching mechanism of the electric spindle 1 through the replaceable tool holder upper part 3-1, the working platform base 4-5 of the performance detection module 4 is fixed to the ground iron 2-3 of the electric spindle support module 2 by bolts, the tool holder feeding module 5 is installed on the working platform base 4-5 of the performance detection module 4, and the tool holder auxiliary feeding mechanism 5-1 cooperates with the groove of the replaceable tool holder lower part 3-2.

[0026] The electric spindle 1 is a tested product for a replaceable broaching mechanism reliability test. Different types of tested electric spindles can be installed on a replaceable broaching mechanism reliability test device to carry out a reliability test.

[0027] The electric spindle support module 2 is a device for testing the electric spindle or the machine tool spindle support, including an electric spindle clamping mechanism 2-1, an electric spindle support column 2-2, and a ground level iron 2-3. Figure 2 . The electric spindle clamping mechanism 2-1 is used to fix and clamp the electric spindle, and prevents the axial movement of the electric spindle through interference fit to ensure the stability of the fixation, and is fixed to the electric spindle support column 2-2 by bolts. A slide groove and a row of threaded holes are provided on the electric spindle support column 2-2, and the electric spindle clamping mechanism 2-1 can be fixedly connected to the threaded holes in different positions to adjust the axial position of the electric spindle on the test device. Taking into account the weight of the test spindle and the dead weight of the supporting parts, in order to simulate the working state of the vertical machine tool and ensure that the supporting part has sufficient rigidity and strength, the electric spindle support column 2-2 is designed as a square column with ribs inside, and is fixed to the ground iron 2-3 by bolts.

[0028] The replaceable simulated tool holder module 3 is the main part of the broach mechanism reliability test device, including a replaceable tool holder upper part 3-1, a replaceable tool holder lower part 3-2, a loading bearing 3-3, and a bearing sleeve 3-4. Figure 3 . In order to simultaneously meet the reliability test and performance test of different types of electric spindles in field tests and bench tests on the same test device, a threaded connection between the replaceable tool handle upper part 3-1 and the replaceable tool handle lower part 3-2 is designed to reduce the manufacturing cost of the simulated tool handle and achieve the replaceability and universality of the simulated tool handle. According to the models of most CNC machine tool electric spindles, the replaceable tool handle upper part 3-1 mainly designed in the present invention mainly includes a BT tool handle and an HSK tool handle. The detailed cross-sectional views of the two types of assembly parts of the replaceable tool handle upper part and the replaceable tool handle lower part can be referred to respectively. Figure 4 and Figure 5. The bottom of the replaceable tool handle lower part 3-2 is provided with a groove of a specific shape, which can cooperate with the raised part at the top of the tool handle auxiliary feeding mechanism 5-1, and realize two kinds of self-locking by rotating a certain angle to prevent the replaceable simulated tool handle module 3 from falling off. The groove of the replaceable tool handle lower part 3-2 is designed to be fan-shaped, and the area of ​​the top of the groove is maximized under the premise of ensuring rotation, so as to achieve the stability of self-locking of the replaceable tool handle lower part 3-2 and the tool handle auxiliary feeding mechanism 5-1. In order to realize dynamic loading and performance testing of the electric spindle 1, the loading bearing 3-3 is installed in the replaceable tool handle lower part 3-2 by interference fit, and the bearing sleeve 3-4 is installed in the loading bearing 3-3 by interference fit. The outer side of the bearing sleeve 3-4 is provided with a groove, which can cooperate with the loading head of the radial force loading device 4-2-1 to increase the force area to ensure the effectiveness of force loading. The loading bearing 3-3 and the bearing sleeve 3-4 are arranged on the outer side of the bottom end of the replaceable tool holder lower part 3-2, which can simulate the actual working condition of the electric spindle 1 being processed on-site on a CNC machine tool, that is, the electric spindle tool tip is subjected to force.

[0029] The performance detection module 4 is an important part for the performance detection of the broaching mechanism, which can detect the dynamic and static stiffness of the joint surface between the spindle and the tool handle, the broaching force and other performance parameters, and mainly includes a sensor module 4-1, a radial force loading module 4-2, an integrated working platform 4-3, a working platform bracket 4-4, and a working platform base 4-5. Figure 6. The sensor module 4-1 and the radial force loading module 4-2 are fixed to the integrated working platform 4-3 by bolts. The two working platform brackets 4-4 are designed in a "Z" shape, with a positioning plane and a threaded hole on the top that can be connected to the integrated working platform 4-3 by bolts, and a positioning plane and a threaded hole on the bottom that can be fixedly connected to the working platform base 4-5 by bolts. The sensor module 4-1 can measure the displacement of the electric spindle 1 in a specific direction, including a laser displacement sensor I 4-1-1, a laser displacement sensor II 4-1-2, a laser displacement sensor III 4-1-3, a sensor guide frame 4-1-4, and a sensor bracket 4-1-5. The laser displacement sensor I 4-1-1, the laser displacement sensor II 4-1-2, and the laser displacement sensor III 4-1-3 are fixedly connected to the sensor guide frame 4-1-4 by bolts, which can adjust the position of the sensor and perform performance detection on the test object. The sensor guide frame 4-1-4 and the sensor bracket 4-1-5 are fixedly connected by bolts. The radial force loading module 4-2 is an auxiliary device for detecting the performance of the broach mechanism, and includes a radial force loading device 4-2-1, a radial force loading device clamp 4-2-2, and a radial force loading device bracket 4-2-3. The radial force loading device 4-2-1 is connected and fixed to the radial force loading device clamp 4-2-2. The radial force loading device clamp 4-2-2 is fixedly connected to the top of the radial force loading device bracket 4-2-3 by bolts. In the present invention, a variety of radial loading devices can be selected for loading, which will not be repeated here.

[0030] The tool holder feeding module 5 can realize the feeding movement of the replaceable simulated tool holder module 3, driving it to push upward to the inner conical surface of the electric spindle 1 and downward to the initial position, so as to complete the automatic tool change process and simulate the tool feeding action of the robot in the actual CNC machine tool. The tool holder feeding module 5 includes a tool holder auxiliary feeding mechanism 5-1, a feeding cylinder 5-2, a cylinder connecting plate 5-3, and an electric turntable 5-4. Figure 7 . The tool holder auxiliary feeding mechanism 5-1 is connected to the feeding cylinder 5-2 by threads. The feeding cylinder 5-2 is fixed to the cylinder connecting plate 5-3 and the electric turntable 5-4 by bolts. The feeding cylinder 5-2 refers to the SC-50*150-S-FB model of AirTac. The electric turntable 5-4 refers to the PX110-200 model of Padway, which can be rotated by a certain angle under the drive of a motor, driving the tool holder auxiliary feeding mechanism 5-1, the feeding cylinder 5-2 and the cylinder connecting plate 5-3 to rotate a corresponding angle, thereby completing the self-locking and unlocking of the replaceable tool holder lower part 3-2 and the tool holder auxiliary feeding mechanism 5-1.

[0031] Specific implementation method 2: Combination Figure 1This embodiment provides a specific implementation scheme of a replaceable broach mechanism reliability test method. The replaceable broach mechanism reliability test method specifically includes the following steps:

[0032] Step 1: According to the model of the machine tool spindle or the test spindle, select the corresponding BT or HSK model of the replaceable tool holder upper part 3-1 and the replaceable tool holder lower part 3-2 for threaded assembly.

[0033] Step 2: Fit the groove at the lower part of the replaceable tool handle after assembly with the tool handle auxiliary feeding mechanism 5-1, rotate the electric turntable 5-4 to a certain angle, realize self-locking of the lower part 3-2 of the replaceable tool handle and the tool handle auxiliary feeding mechanism 5-1, and place the replaceable simulated tool handle module 3 in the initial position.

[0034] Step 3: Performing a functional test on the broaching mechanism is the basis for conducting a reliability test on the broaching mechanism. Faults can be triggered by repeated tool changing actions, and the number of tool changes, tool changing time, electric spindle tool operation time, electric spindle tool loading time, etc. can be recorded to provide data for the reliability study of the broaching mechanism. The feed cylinder 5-2 brings the tool holder auxiliary feed mechanism 5-1 up from the initial position to push the replaceable simulated tool holder module 3 to the inner conical surface position of the electric spindle 1. The broaching mechanism inside the electric spindle 1 performs broaching, so that the inner conical surface of the electric spindle 1 is tightly combined with the outer conical surface of the replaceable tool holder upper part 3-1. The electric turntable 5-4 rotates a certain angle, the replaceable tool holder lower part 3-2 and the tool holder auxiliary feed mechanism 5-1 are released from self-locking, and the feed cylinder 5-2 brings the tool holder auxiliary feed mechanism 5-1 down to the initial position. Turn on the frequency converter that controls the electric spindle, control the electric spindle to rotate with the tool at a certain speed, and make the radial force loading device 4-2-1 contact with the groove of the bearing sleeve 3-4, and dynamically load the running electric spindle to simulate the real working condition. The electric spindle 1 runs with the tool for a period of time, unload the radial force loading device 4-2-1, and stop the operation of the electric spindle 1. The feed cylinder 5-2 carries the tool holder auxiliary feed mechanism 5-1 from the initial position to the inside of the groove of the replaceable tool holder lower part 3-2, and the electric turntable 5-4 rotates in the opposite direction by a certain angle, and the replaceable tool holder lower part 3-2 and the tool holder auxiliary feed mechanism 5-1 are self-locked. The feed cylinder 5-2 carries the tool holder auxiliary feed mechanism 5-1 and the replaceable simulated tool holder module 3 down to the initial position, and repeats the above steps.

[0035] Step 4: Perform a performance test on the broaching mechanism to obtain the static and dynamic stiffness of the interface between the spindle and the tool handle, the broaching force and other performance parameters, and use them as the criterion for the static and dynamic characteristics and fault diagnosis of the electric spindle. After the functional test, the broaching detection device is tightened through the broaching mechanism inside the electric spindle 1 to obtain the broaching force. Adjust the position of the laser displacement sensor II 4-1-2 on the sensor guide rail frame 4-1-4, and make the test direction of the laser displacement sensor II 4-1-2 and the force loading direction of the radial force loading device 4-2-1 in a straight line. Contact the radial force loading device 4-2-1 with the groove of the bearing sleeve 3-4, and apply different radial forces to obtain the static stiffness. Turn on the inverter that controls the electric spindle to control the electric spindle to rotate with the tool at a certain speed. Contact the radial force loading device 4-2-1 with the groove of the bearing sleeve 3-4, and apply different radial forces to obtain the dynamic stiffness. Adjust the positions of the laser displacement sensor I4-1-1 and the laser displacement sensor III4-1-3 on the sensor guide frame 4-1-4, and make the test directions of the laser displacement sensor I4-1-1 and the laser displacement sensor III4-1-3 at 90° to obtain rotation accuracy.

[0036] Step 5: Perform a fault diagnosis test on the broaching mechanism, and diagnose whether the broaching mechanism has a fault based on the obtained performance test results and the transient vibration during the broaching process. The vibration sensor is magnetically attached to the end of the electric spindle 1, and the cylinder pressure sensor is installed on the tool-breaking cylinder of the electric spindle 1. Perform a single functional test of the broaching mechanism, and obtain and record the transient vibration values ​​of the broaching and tool-loosening and the tool-breaking cylinder pressure values.

[0037] The embodiment of the present invention takes the broaching mechanism, a key component of the electric spindle, as the research object and studies the reliability of the broaching mechanism. Based on the established test device, the present invention can perform functional tests, performance detection tests and fault diagnosis tests on the broaching mechanisms of electric spindles of different models. Among them, the functional test and performance detection test are the basis of the reliability test and provide a basis for the fault diagnosis test. The functional test of repeated tool change may trigger a specific fault of the broaching mechanism and cause a change in a specific performance parameter, thereby judging whether a fault occurs and determining the fault mode.

[0038] By repeating the reliability test steps of the broach mechanism and analyzing the accumulated test data, the research contents that can be realized mainly include the following aspects:

[0039] 1. The relationship between disc spring related failure modes and broaching force, dynamic and static stiffness, and rotation accuracy;

[0040] 2. The relationship between disc spring related failure modes and the transient vibration of pulling and loosening the knife;

[0041] 3. The relationship between disc spring related failure modes and the pressure value of the knife cylinder;

[0042] 4. The relationship between the failure modes of the knife-beating cylinder and the pressure value of the knife-beating cylinder;

[0043] 5. The relationship between the pull claw related failure mode and the pull tool force, dynamic and static stiffness, and rotation accuracy;

[0044] 6. The relationship between the claw-related failure modes and the transient vibration of the pulling and releasing tools;

[0045] 7. The relationship between various performance parameters of the electric spindle;

[0046] 8. The relationship between the number of tool changes, tool change time, electric spindle tool operation time, electric spindle tool loading time and mean time between failures (MTBF).

[0047] In summary, the present invention proposes a replaceable broaching mechanism reliability test device to realize automatic feeding and tool changing of the tool handle, and can perform functional tests, performance detection tests, and fault diagnosis tests. The reliability test of the device provides a data basis for the reliability research of the broaching mechanism, so as to solve the limitation that the current electric spindle reliability test device cannot perform reliability tests on key components.

Claims

1. A replaceable broach mechanism reliability test device, characterized in that: The invention comprises five modules, namely, an electric spindle (1), an electric spindle support module (2), a replaceable simulated tool holder module (3), a performance detection module (4), and a tool holder feeding module (5); the electric spindle (1) is connected and fixed to an electric spindle clamping mechanism (2-1) of the electric spindle support module (2); the replaceable simulated tool holder module (3) is connected and fixed to an internal broaching mechanism of the electric spindle (1) via an upper part of a replaceable tool holder (3-1); the working platform base (4-5) of the performance detection module (4) is connected and fixed to a ground level iron (2-3) of the electric spindle support module (2) via bolts; the tool holder feeding module (5) is connected and fixed to an internal broaching mechanism of the electric spindle (1) via an upper part of a replaceable tool holder (3-1); 5) is installed on the working platform base (4-5) of the performance detection module (4), and the tool holder auxiliary feeding mechanism (5-1) of the tool holder feeding module (5) cooperates with the groove of the replaceable tool holder lower part (3-2) of the replaceable simulated tool holder module (3); the electric spindle support module (2) includes an electric spindle clamping mechanism (2-1), an electric spindle support column (2-2), and a ground iron (2-3); the electric spindle clamping mechanism (2-1) is fixed to the electric spindle support column (2-2) by bolts; the electric spindle support column (2-2) is fixed to the ground iron (2-3) by bolts; The electric spindle support column (2-2) is provided with a slide groove and a row of threaded holes, which are fixedly connected to the threaded holes at different positions through the electric spindle clamping mechanism (2-1) to adjust the axial position of the electric spindle on the test device; The replaceable simulated toolholder module (3) comprises a replaceable toolholder upper portion (3-1), a replaceable toolholder lower portion (3-2), a loading bearing (3-3), and a bearing sleeve (3-4); the replaceable toolholder upper portion (3-1) comprises a BT toolholder and an HSK toolholder, and the replaceable toolholder upper portion (3-1) and the replaceable toolholder lower portion (3-2) are connected via threads; the loading bearing (3-3) is installed on the replaceable toolholder lower portion (3-2) by interference fit; the bearing sleeve (3-4) is installed on the loading bearing (3-3) by interference fit, so as to realize dynamic loading of the electric spindle (1) by the radial force loading device (4-2-1) of the performance detection module (4); The performance detection module (4) comprises a sensor module (4-1), a radial force loading module (4-2), an integrated working platform (4-3), a working platform bracket (4-4), and a working platform base (4-5); the sensor module (4-1) is fixed to the integrated working platform (4-3) by bolts; the radial force loading module (4-2) is fixed to the integrated working platform (4-3) by bolts; the integrated working platform (4-3) is connected to the tops of the two working platform brackets (4-4) by bolts; the bottoms of the two working platform brackets (4-4) are fixedly connected to the working platform base (4-5) by bolts; The sensor module (4-1) comprises a laser displacement sensor I (4-1-1), a laser displacement sensor II (4-1-2), a laser displacement sensor III (4-1-3), a sensor guide rail frame (4-1-4), and a sensor bracket (4-1-5); the laser displacement sensor I (4-1-1), the laser displacement sensor II (4-1-2), and the laser displacement sensor III (4-1-3) are fixedly connected to the sensor guide rail frame (4-1-4) by bolts to adjust the sensor positions and perform performance testing on the test object; The sensor guide rail frame (4-1-4) is fixedly connected to the sensor bracket (4-1-5) by bolts; the radial force loading module (4-2) comprises a radial force loading device (4-2-1), a radial force loading device clamp (4-2-2), and a radial force loading device bracket (4-2-3); the radial force loading device (4-2-1) is connected and fixedly connected to the radial force loading device clamp (4-2-2); the radial force loading device clamp (4-2-2) is fixedly connected to the top of the radial force loading device bracket (4-2-3) by bolts; The tool holder feeding module (5) comprises a tool holder auxiliary feeding mechanism (5-1), a feeding cylinder (5-2), a cylinder connecting plate (5-3), and an electric turntable (5-4); the tool holder auxiliary feeding mechanism (5-1) and the feeding cylinder (5-2) are connected via threads; the feeding cylinder (5-2) and the cylinder connecting plate (5-3) and the electric turntable (5-4) are fixed via bolts.

2. The reliability test method for a replaceable broach mechanism using the test device according to claim 1 is characterized in that: The following steps are involved: According to the model of the machine tool spindle or the test spindle, select the corresponding replaceable tool holder upper part (3-1) and the replaceable tool holder lower part (3-2) for assembly; The groove at the bottom of the replaceable tool handle after assembly is matched with the tool handle auxiliary feeding mechanism (5-1) to achieve self-locking of the two and to push the replaceable simulated tool handle module (3) to the inner conical surface of the electric spindle (1); Conduct functional tests on the broaching mechanism and record the number of tool changes and tool change time to provide data basis for reliability analysis; Perform performance testing on the broaching mechanism to obtain the dynamic and static stiffness of the spindle and tool handle interface and the broaching force performance parameters, which will be used as the criterion for the static and dynamic characteristics of the electric spindle and fault diagnosis; Conduct fault diagnosis test on the broach mechanism, and diagnose the fault of the broach mechanism based on the obtained performance test results and transient vibration during the broaching process; Among them, when conducting the broach mechanism functional test, it specifically includes: The feed cylinder (5-2) carries the tool holder auxiliary feed mechanism (5-1) to push the replaceable simulated tool holder module (3) upward from an initial position to the inner conical surface of the electric spindle (1); The internal broaching mechanism of the electric spindle (1) performs broaching so that the inner conical surface of the electric spindle (1) is tightly combined with the outer conical surface of the upper part (3-1) of the replaceable tool holder; The electric turntable (5-4) rotates a certain angle, the lower part of the replaceable tool handle (3-2) and the tool handle auxiliary feeding mechanism (5-1) are released from self-locking, and the feeding cylinder (5-2) leads the tool handle auxiliary feeding mechanism (5-1) downward to the initial position; Turning on the frequency converter that controls the electric spindle to control the electric spindle to rotate with the tool at a certain speed, making the radial force loading device (4-2-1) contact the groove of the bearing sleeve (3-4), and dynamically loading the running electric spindle to achieve simulation of real working conditions; The electric spindle (1) is operated with the cutter for a period of time, the radial force loading device (4-2-1) is unloaded, and the operation of the electric spindle (1) is stopped; The feeding cylinder (5-2) carries the tool holder auxiliary feeding mechanism (5-1) upward from the initial position to the inside of the groove of the replaceable tool holder lower part (3-2), and the electric turntable (5-4) rotates in the opposite direction by a certain angle, so that the replaceable tool holder lower part (3-2) and the tool holder auxiliary feeding mechanism (5-1) are self-locked; The feeding cylinder (5-2) carries the tool holder auxiliary feeding mechanism (5-1) and the replaceable simulated tool holder module (3) downward to an initial position; Repeat the above steps and record the number of tool changes, tool change time, electric spindle tool operation time, and electric spindle tool loading time.

3. The reliability test method of the replaceable broach mechanism according to claim 2, characterized in that: in, When conducting the broach mechanism performance test, it specifically includes: After the functional test, the broaching detection device is tightened through the broaching mechanism inside the electric spindle (1) to obtain the broaching force; Adjusting the position of the laser displacement sensor II (4-1-2) on the sensor guide rail frame (4-1-4) so ​​that the test direction of the laser displacement sensor II (4-1-2) and the force loading direction of the radial force loading device (4-2-1) are in a straight line; The radial force loading device (4-2-1) is brought into contact with the groove of the bearing sleeve (3-4) to apply different radial forces to obtain static stiffness; Turn on the frequency converter that controls the electric spindle to control the electric spindle to rotate with the tool at a certain speed; The radial force loading device (4-2-1) contacts the groove of the bearing sleeve (3-4) and applies different radial forces to obtain dynamic stiffness; The positions of the laser displacement sensor I (4-1-1) and the laser displacement sensor III (4-1-3) are adjusted on the sensor guide rail frame (4-1-4), and the test directions of the laser displacement sensor I (4-1-1) and the laser displacement sensor III (4-1-3) are made to be 90 degrees, so as to obtain rotation accuracy.

4. The replaceable broach mechanism reliability test method according to claim 3, characterized in that: in, When conducting the broach mechanism fault diagnosis test, it specifically includes: The vibration sensor is adsorbed to the end of the electric spindle (1) by magnetic force, and the cylinder pressure sensor is installed on the cutting cylinder of the electric spindle (1); A single functional test of the broaching mechanism is carried out to obtain the transient vibration values ​​of broaching and loosening and the pressure value of the tool-beating cylinder.

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