An adaptive efficiency improvement system for a machine tool unit

Abstract

The present invention discloses a machine tool unit adaptive efficiency improvement system. The system includes a management host, a control box, and a machine tool control program unit. The management host is communicatively connected to a plurality of control boxes, and each control box is respectively communicatively connected to a machine tool control program unit. The machine tool control program unit is disposed in the machine tool unit to control the working parameters of the machine tool. The working parameters of the machine tool can be automatically adjusted according to the internal load condition, the tool number, and the position condition of the manipulator. The management host performs overall control on the control boxes to improve the operation efficiency of the machine tool.

Description

Technical Field

[0001] The present invention relates to the technical field of machining equipment, and particularly relates to a machine tool unit adaptive efficiency improvement system. Background Art

[0002] At present, the capabilities of existing machining machine tools have not been fully utilized. In the wheel hub processing industry, the number of wheel shape replacements is large and the quantity is also large. There is an urgent need to improve the efficiency of the machine tools. Through big data analysis, when the machine tools are in mass production, the load is about 40, and the efficiency has not been maximized. Both the machine tool manufacturers and the motors can at least withstand a load of about 60. Therefore, there is still a large room for efficiency improvement. Moreover, in the case of frequent wheel shape replacement, if the machining program is optimized, a large amount of manpower is required to track and modify the program, and it is impossible to determine whether there is an overload situation, which may cause damage to the machine tool and quality problems. In addition, for integrated automatic units, there is more downtime caused by the waiting and cooperation of the manipulators. Summary of the Invention

[0003] Therefore, the present invention provides a machine tool unit adaptive efficiency improvement system to solve the problems that the existing machining machine tools cannot maximize the efficiency, optimizing requires a large amount of manpower to track and modify the program, and it is impossible to determine whether there is an overload situation, and there is more downtime caused by the waiting and cooperation of the manipulators.

[0004] To achieve the above object, the present invention provides the following technical solution: A machine tool unit adaptive efficiency improvement system, the system includes a management host, a control box, and a machine tool control program unit. The management host is communicatively connected to a plurality of control boxes, and each control box is respectively communicatively connected to a machine tool control program unit. The machine tool control program unit is disposed in the machine tool unit. The management host is used to control each control box and input the control parameters of each control box. The control box is used to control the machine tool control program unit and automatically adjust the feed rate of each machine tool in the machine tool unit according to the control parameters. The machine tool control program unit is used for collecting and controlling the working parameters of the machine tool unit, realizing the control of the machine tool load, and staggering the machining completion times of each machine tool to avoid simultaneous machining completion, ensuring the shortest waiting time between the machine tool and the manipulator, and improving the efficiency.

[0005] Further, the management host and the control box communicate through the WCF-TCP protocol, and the control box and the machine tool control program unit communicate through the FOCAS protocol.

[0006] Further, the control parameters input in the management host include load limit values, rough machining tool numbers, and efficiency improvement ratio limit values, and the machine tool unit working parameters collected by the machine tool control program unit include robot signals, tool numbers, spindle loads, servo axis loads, and feed rates.

[0007] Further, the control box is used to initially count the machining times of each machine tool unit in the machine tool unit, determine the optimal efficiency improvement ratio to be set for each machine tool according to the machining times of each machine tool, and the efficiency improvement ratio is the modification proportional coefficient of the machine tool feed rate.

[0008] Further, the control box is specifically used to, by combining the characteristics of the hub cutting process, not consider the tool mark problem during rough machining. Therefore, the efficiency improvement ratio is modified during rough machining, and its load is controlled not to exceed the specified limit value to avoid damaging the machine tool. When rough machining is completed or the tool is changed, the efficiency improvement ratio is automatically restored to the initial value.

[0009] Further, the machine tool control program unit is specifically used to obtain the signal of the robot. The signals of the robot include wheel picking signals and wheel placing signals. After the control box obtains that the signal of the robot is the ready-to-place-wheel signal, the control box controls the machine tool control program unit to obtain the currently used tool number. If the currently used tool number is the set rough turning tool number, the efficiency improvement ratio is changed to the set efficiency improvement ratio, and then the feed rate is modified.

[0010] Further, the machine tool control program unit is specifically further used to obtain the spindle load and servo axis load of the machine tool. The control box detects whether they exceed the load limit value according to the statistically obtained spindle load and servo axis load, and modifies the efficiency improvement ratio according to the result to modify the feed rate. When the load is lower than the limit value, the efficiency improvement ratio is increased, and when the load is higher than the limit value, the efficiency improvement ratio is decreased. The modification of the efficiency improvement ratio does not exceed the efficiency improvement ratio limit value.

[0011] Further, the control box is specifically further used to, according to the overload characteristic curve of the motor, give an alarm when the continuous load exceeds a certain limit value.

[0012] Further, the management host further includes a storage unit for storing the collected working parameter data and relevant control parameter data, so as to obtain the variation relationship between the load and the efficiency improvement ratio through big data analysis based on the stored data, and optimize the efficiency improvement of the machine tool.

[0013] The present invention has the following advantages:

[0014] An adaptive efficiency improvement system for a machine tool unit proposed by the present invention. The system includes a management host, a control box, and a machine tool control program unit. The management host is communicatively connected to a plurality of control boxes, and each control box is respectively communicatively connected to a machine tool control program unit. The machine tool control program unit is disposed in the machine tool unit. The load limit value of the machine tool can be set according to the machine tool situation, and then the feed rate can be modified according to an algorithm. After writing the efficiency improvement rate, the efficiency is automatically improved. According to the machine tool load situation, it is modified in real time. When the load is lower than the limit value, the efficiency improvement rate is increased, and when it is higher than the limit value, the efficiency improvement rate is decreased to maintain the stability of its load. At the same time, it avoids damage to the machine tool caused by overloading. Moreover, by setting the rough machining tool number, quality problems caused by tool mark damage are prevented. And according to the signals of the robot for taking and placing wheels and the processing time, the feed rates of each unit can be set respectively to ensure the shortest waiting time for the robot. And various parameters can be stored to lay a foundation for subsequent data analysis. Each control box corresponds to one unit to ensure its stability. At the same time, centralized control is carried out through the management host to reduce the operation time and improve the efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only exemplary, and for those of ordinary skill in the art, without creative efforts, other implementation drawings can be obtained according to the provided drawings.

[0016] Figure 1 FIG. is a schematic structural diagram of an adaptive efficiency improvement system for a machine tool unit provided in Embodiment 1 of the present invention;

[0017] Figure 2 FIG. is a schematic structural diagram of a machine tool unit in an adaptive efficiency improvement system for a machine tool unit provided in Embodiment 1 of the present invention;

[0018] Figure 3 FIG. is a comparison diagram of the load before and after in an adaptive efficiency improvement system for a machine tool unit provided in Embodiment 1 of the present invention;

[0019] Figure 4 FIG. is a schematic diagram of the working process between each machine tool and the robot in a machine tool unit in an adaptive efficiency improvement system for a machine tool unit provided in Embodiment 1 of the present invention;

[0020] Figure 5 FIG. is an analysis diagram of the processing time of each machine tool in a machine tool unit in an adaptive efficiency improvement system for a machine tool unit provided in Embodiment 1 of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] The following specific embodiments illustrate the implementation manners of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0022] Embodiment 1

[0023] As Figure 1 shown, this embodiment proposes a machine tool unit adaptive efficiency improvement system, which includes a management host, a control box, and a machine tool control program unit. The management host is communicatively connected to multiple control boxes, and each control box is respectively communicatively connected to a machine tool control program unit. The machine tool control program unit is arranged in the machine tool unit. The management host is used to control each control box and input the control parameters of each control box. The control box is used to control the machine tool control program unit and automatically adjust the feed rate of each machine tool in the machine tool unit according to the control parameters. The machine tool control program unit is used for collecting and controlling the working parameters of the machine tool unit, realizing the control of the machine tool load, staggering the machining completion times of each machine tool, avoiding simultaneous machining completion, ensuring the shortest waiting time between the machine tool and the manipulator, and improving the efficiency.

[0024] Specifically, the management host and the control box communicate through the WCF-TCP protocol, and the control box and the machine tool control program unit communicate through the FOCAS protocol. Through the management host, various parameters required by the control box can be input, including the load limit value, rough machining tool number, and efficiency improvement rate limit value, and the start and stop of the control box can be controlled. By modifying the PMC program of the FANUC machine tool, it is transformed into a machine tool program control unit. The control box can modify parameters in the machine tool control program unit to modify parameters such as the internal feed rate of the machine, and does not affect the normal use of the feed rate knob. In this embodiment, the machine feed rate cannot be directly modified, and the modification of the machine feed rate is achieved by modifying the efficiency improvement rate. The efficiency improvement rate is the modification ratio coefficient of the machine tool feed rate. The control box can also store the spindle load, servo load, machining time, feed rate, etc. of each machine tool to prepare for further big data analysis.

[0025] The specific implementation process is as follows:

[0026] First, through the management host, input the load limit value, rough turning tool number, and maximum feed rate required in the control box, and then transmit them to the machine tool. After that, the machine tool will operate according to the set algorithm logic. If the software cannot be configured on the server, due to high requirements for real-time performance and security, such as the feed rate not being modified due to untimely transmission caused by system crashes, etc., it may cause problems such as tool breakage. Therefore, a control box is required to configure for one machine.

[0027] The adjustment structure of the machine tool unit is as Figure 2 shown. When the software starts running, it first learns and analyzes the processing time of the three machine tools in the machine tool unit. Through the instructions of the manipulator to pick up and place the wheels, combined with the processing time, it gives the optimal efficiency improvement ratio that each of the three machine tools needs to set, so that the three machine tools can complete production at intervals, so that the manipulator can pick up and place the wheels separately, reducing the waiting time. For example, for those with a longer production time, shorten its production time by adjusting the efficiency improvement ratio. For those with a shorter production time, adjust the efficiency improvement ratio to extend the production time. During control, it is judged according to the processing time of each machine tool in the unit. According to the time of each machine tool, different efficiency improvement ratios are selected, so that the manipulator can pick up the wheels separately. And the software starts to execute when the manipulator is ready to deliver the wheel, and stops the software when the manipulator is ready to pick up the wheel.

[0028] After confirmation, start running to read the signal of the manipulator. When the signal of preparing to place the wheel is read, read the currently used tool number. If the currently used tool number is the specified rough turning tool number, change its efficiency improvement ratio to the set efficiency improvement ratio, thereby increasing the feed rate. In addition, read the spindle load and servo axis load of the machine tool and record them. At the same time, if the spindle load and servo axis load exceed the set overload value for a certain period of time, an alarm will be given and the machine will stop, and it will loop continuously. And in order to minimize the writing frequency and reduce the CPU processing of the machine tool, when the machine tool first reads that the current tool number is the rough turning tool number, modify its efficiency improvement ratio, and do not modify it afterwards. However, in order to avoid software control interruption caused by mid-course disconnection, software crashes, etc., and at this time it is in the rough machining period and the feed rate has been modified, which will cause the tool marks to become thicker and quality problems will occur. Therefore, it is set in the machine tool program control unit that when each segment of the internal machining program of the machine tool ends or the tool is changed, its efficiency improvement ratio is reset to the value before modification, so as to avoid quality problems caused by unexpected situations and make it controllable. Therefore, during the loop, there will be a situation where the current tool number is the rough machining tool number, but the efficiency improvement ratio is the original value and has not been modified. When this situation occurs, write the efficiency improvement ratio again. When the finish machining tool number is read, the efficiency improvement ratio is restored to the original efficiency improvement ratio, and the values of the spindle load and servo axis load during rough machining previously counted are calculated. If it exceeds the specified load limit value, subtract one from the efficiency improvement ratio. If it is lower than the specified load limit value that exceeds, add one to the efficiency improvement ratio, but the efficiency improvement ratio cannot be greater than the specified maximum efficiency improvement ratio.

[0029] The software algorithm logic is based on Figure 3 the developed big data analysis graph, classifies and analyzes the wheel shape and machine tool replaced each time, and finally obtains the algorithm logic.

[0030] The control relationship of the software for the three machine tools in the machine tool unit is as Figure 4 shown. Before modification, it was possible that all three machine tools finished processing simultaneously and were waiting for the action of the manipulator, or while some machine tools were waiting for the manipulator to move the wheel hub away, other machine tools completed production. This would cause the machines to wait for the manipulator to complete the action, resulting in a great waste of time. After modification, the relationship is changed to that the three machine tools process sequentially and wait for the action of the manipulator. Based on the big data of the processing time of the three machine tools, analysis is carried out, and the corresponding efficiency improvement ratio is given to stagger the processing completion time of the machine tools, avoid simultaneous processing completion, and thus wait for the action of the manipulator, as Figure 5 , and finally the logic of the algorithm is obtained.

[0031] In view of the characteristics of the wheel hub processing industry, where several machine tools need to form a unit to cooperate to complete the processing of the wheel hub, the digital twin technology is used to simulate and simulate the process of specific wheel type machine tool processing and the operation of the manipulator to transport the wheels. According to the process requirements of different processing parts of the wheel hub machine tool and the process requirements of special wheel types, such as the machining center is responsible for drilling, and the first-order machine tool is responsible for cutting the outside of the wheel hub, etc., different parameter intervals are assigned to each machine tool, so as to separate the production completion time of each machine tool, ensure better cooperation between the manipulator and each machine tool, and prevent the manipulator and each machine tool from waiting for each other. By this means, the construction of an expert model is completed, and a set of applicable models is established for the start and completion signals of the manipulator and the parameters of each machine tool;

[0032] For the efficiency improvement ratio of a single machine tool, according to the load values of the spindle motor and servo motor of the machine tool, using big data analysis technology and the process requirements of the wheel hub industry for drilling, the relationship between the load curve and the efficiency improvement ratio is analyzed for non-drilling machine tools such as the first-order and second-order machine tools, and deep learning is carried out to obtain the safe efficiency improvement ratio that can be achieved at each point. For drilling machine tools, big data technology is used to analyze the situation of the turret hitting the drill bit, and the relationship between its efficiency improvement ratio and load is obtained through deep learning.

[0033] Comparison of the characteristics of other similar systems:

[0034] In view of the characteristics of the wheel hub processing industry, where different parts of different wheel type wheel hubs are processed separately, the data of positions such as cutting the rim and drilling are separately statistically analyzed for regression analysis, and the correlation is more accurate. Deep learning is used to maximize the efficiency improvement during the processing of each part;

[0035] In the hub machining industry, where several machine tools and manipulators cooperate, this system constructs a model that enables better cooperation between the machine tools and manipulators and reduces waiting time. By assigning different parameters to the machine tools, the machining can be completed sequentially;

[0036] Fully consider the influence of blank deformation on the instantaneous load. By recording the average value of the same point during operation, it is ensured that there is no adaptive error adjustment caused by blank deformation.

[0037] For the benefits of industry promotion:

[0038] It can better protect the cutting tools. When there is a large load during machining by the machine tool, the efficiency reduction ratio is reduced in advance to avoid excessive wear of the cutting tools caused by too fast operation during cutting;

[0039] It can better extend the service life of the motor. The overload characteristic curve of the motor is embedded in the monitoring. When the motor load exceeds the overload characteristic curve, the parameters are adjusted adaptively to extend the service life of the motor;

[0040] For the unit machining mode in the hub machining industry, due to the situation of simultaneous machining completion, the machine tool waits for the manipulator or the manipulator waits for the machine tool, and the efficiency of the manipulator and the machine tool cannot be fully utilized. According to the lean production theory, the waiting time is minimized to the greatest extent. By using the model of this system, the unit waiting time can be minimized, the utilization rate of the unit can be fully improved, and lean production can be achieved.

[0041] Although the present invention has been described in detail with general descriptions and specific embodiments above, based on the present invention, some modifications or improvements can be made, which are obvious to those skilled in the art. Therefore, these modifications or improvements made without departing from the spirit of the present invention all fall within the scope of protection required by the present invention.

Claims

1. An adaptive efficiency improvement system for a machine tool unit, characterized in that, The system includes a management host, control boxes, and a machine tool control program unit. The management host is communicatively connected to multiple control boxes, and each control box is respectively communicatively connected to a machine tool control program unit. The machine tool control program unit is disposed in the machine tool unit. The management host is used to control each control box and input the control parameters of each control box. The control box is used to control the machine tool control program unit and automatically adjust the feed rate of each machine tool in the machine tool unit according to the control parameters. The machine tool control program unit is used for collecting and controlling the working parameters of the machine tool unit, realizing the control of the machine tool load, staggering the machining completion times of each machine tool, avoiding simultaneous machining completion, ensuring the shortest waiting time between the machine tool and the manipulator, and improving efficiency; The machine tool control program unit is specifically used to obtain the signals of the manipulator. The signals of the manipulator include a wheel picking signal and a wheel placing signal. After the control box obtains that the signal of the manipulator is a ready-to-place-wheel signal, it controls the machine tool control program unit to obtain the currently used tool number. If the currently used tool number is the set rough turning tool number, the efficiency improvement ratio is changed to the set efficiency improvement ratio, and then the feed rate is modified.

2. The adaptive efficiency improvement system for a machine tool unit according to claim 1, characterized in that The management host communicates with the control box through the WCF-TCP protocol, and the control box communicates with the machine tool control program unit through the FOCAS protocol.

3. An adaptive efficiency improvement system for a machine tool unit according to claim 1, characterized in that, The control parameters input in the management host include a load limit value, a rough machining tool number, and an efficiency improvement ratio limit value. The working parameters of the machine tool unit collected by the machine tool control program unit include manipulator signals, tool numbers, spindle loads, servo axis loads, and feed rates.

4. The adaptive efficiency improvement system for a machine tool unit according to claim 3, wherein, The control box is used to initially count the machining times of each machine tool in the machine tool unit and determine the optimal efficiency improvement ratio to be set for each machine tool according to the machining times of each machine tool. The efficiency improvement ratio is the modification proportional coefficient of the machine tool feed rate.

5. An adaptive efficiency improvement system for a machine tool unit according to claim 4, characterized in that, The control box is specifically used to, by combining the characteristics of the hub cutting process, not consider the tool mark problem during rough machining. Therefore, the efficiency improvement ratio is modified during rough machining, and its load is controlled not to exceed the specified limit value to avoid damaging the machine tool. When rough machining ends or the tool is changed, the efficiency improvement ratio is automatically restored to the initial value.

6. The adaptive efficiency improvement system for a machine tool unit according to claim 5, characterized in that, The machine tool control program unit is specifically further used to obtain the spindle load and servo axis load of the machine tool. The control box detects whether the spindle load and servo axis load exceed the load limit value according to the statistical results, modifies the efficiency improvement ratio according to the results, and then modifies the feed rate. When the load is lower than the limit value, the efficiency improvement ratio is increased; when the load is higher than the limit value, the efficiency improvement ratio is decreased. The modification of the efficiency improvement ratio does not exceed the efficiency improvement ratio limit value.

7. An adaptive efficiency improvement system for a machine tool unit according to claim 1, characterized in that, The control box is specifically further used to perform an alarm according to the overload characteristic curve of the motor when the continuous load exceeds a certain limit value.

8. An adaptive efficiency improvement system for a machine tool unit according to claim 1, characterized in that The management host further includes a storage unit, which is used to store the collected working parameter data and relevant control parameter data, so as to obtain the change relationship between the load and the efficiency improvement ratio through big data analysis based on the stored data, and optimize the efficiency improvement of the machine tool.

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