An intelligent tool change method, system and storage medium

Abstract

The present invention relates to a tool changing method and system for a numerically controlled machine tool, and particularly to an intelligent tool changing method, system and storage medium. It overcomes the problems of frequent tool changing and irregular tool changing existing in the existing tool changing method based on the tooling tool management system. The present invention sets a tool changing time period and a blackout time period. During the tool changing time period, by judging the remaining machining time of the tool and the continuous running time of the production line within the tool changing time period, the tool with the remaining life lower than the set warning life value is replaced, and at the same time, the tool with the remaining machining time less than the continuous running time of the production line within the tool changing time period is replaced. In addition, before entering the blackout time period, the tool with the remaining machining time less than the continuous running time of the production line during the blackout time period is replaced. The present invention centrally replaces the tools during the tool changing time period, reduces the tool changing frequency, improves the production line operation rate, makes the tool changing time period and the continuous running time flexibly controllable, and meets the needs of a unmanned chemical plant.

Description

Technical Field

[0001] The present invention relates to a tool changing method and system for a numerical control machine tool, and particularly to an intelligent tool changing method, system and storage medium. Background Art

[0002] In the machinery manufacturing industry, when the tool life of a numerical control machine tool is exhausted or the processed product is changed, replacement is required. Previously, it was mainly workers who replaced the tools based on experience. Currently, with the digital transformation, some advanced manufacturing enterprises have started to manage tools through TLM (Tooling and Tool Management System). However, in terms of tool replacement, TLM only monitors the tool life and alarms when the tool life reaches the warning life to remind workers to change the tool. Although this method makes the in-machine state of the tool transparent, greatly improves the timeliness of tool changing, and reduces the risk of overusing the tool. However, this method has the situation of frequent tool changing and irregular tool changing, and the tool changing frequency of workers remains high and has not changed. For unmanned factories, it is unrealistic to have workers change tools frequently and irregularly. According to this situation, the present invention has developed an intelligent tool changing strategy calculation method through research and analysis of the on-site situation, tooling and tool management system, and unmanned factory, which can calculate the estimated tool changing time of the tool based on the real-time life of the tool, guide workers to perform centralized tool changing, and control the entire tool changing process. Currently, there is no related technology at home and abroad. Summary of the Invention

[0003] The object of the present invention is to provide an intelligent tool changing method, system and storage medium, which overcome the problems of frequent tool changing and irregular tool changing existing in the existing tool changing method based on the tooling and tool management system. The present invention can calculate the estimated tool changing time of the tool based on the real-time life of the tool, guide workers to perform centralized tool changing, and control the entire tool changing process.

[0004] The technical solution of the present invention is to provide an intelligent tool changing method, which is characterized in that the real-time life of all tools on each production line and each machine tool is obtained in real time; based on the real-time life, the following processes are respectively executed during the tool changing time period (when there are workers on site) and when entering the blackout time period (when there are no workers on site):

[0005] Tool changing time period:

[0006] Step 1a: Calculate the remaining life of all tools according to the real-time life. If the remaining life is lower than the set warning life value, issue a warning and mark the corresponding tool with a first warning mark;

[0007] At the same time, convert the remaining life of the other tools into the remaining processing time. When the remaining processing time is less than the set value of the continuous operation time of its production line during the tool changing time period, mark the corresponding tool with a second warning mark;

[0008] Step 2a: According to the first warning mark and the second warning mark, sort the cutting tools according to the urgency of tool change, generate tool change information, and send the tool change information to the site to guide the workers to change the cutting tools. When changing the cutting tool marked with the first warning mark, it is also necessary to change the cutting tool marked with the second warning mark;

[0009] Enter the blackout period:

[0010] Step 1b: Within the set time before entering the blackout period, calculate the remaining life of the corresponding cutting tool according to the real-time life;

[0011] Step 2b: Convert the remaining life of each cutting tool into the remaining processing time. When the remaining processing time is less than the set value of the continuous running time of the production line during the blackout period, before entering the blackout period, send out a warning and mark the corresponding cutting tool with the first warning mark, generate tool change information, and send the tool change information to the site to guide the workers to change the cutting tools.

[0012] Further, Step 2a is specifically as follows:

[0013] Step 2a1: Judge the urgency of tool change for each cutting tool in each machine tool according to the first warning mark and the second warning mark, and sort the cutting tools in each machine tool according to the urgency of tool change;

[0014] Step 2a2: Judge the urgency of tool change for each machine tool in each production line according to the first warning mark and the second warning mark, and sort the machine tools in each production line according to the urgency of tool change;

[0015] Step 2a3: Judge the urgency of tool change for each production line according to the first warning mark and the second warning mark, and sort each production line according to the urgency of tool change;

[0016] Step 2a4: Dynamically display the estimated tool change time (remaining processing time) of each production line. If there is a conflict in the tool change time, advance the production line that triggers the tool change warning first by a time period. Otherwise, generate tool change information according to the production line order, the machine tool order within the production line, and the tool order on the machine tool, and send the tool change information to the site to guide the workers to change all the cutting tools with a life less than N in each production line, where N is the set value of the continuous running time of the production line.

[0017] Further, the remaining processing time is converted from the remaining life of the cutting tool by the following formula:

[0018] Remaining processing time = remaining life (pieces) × workpiece cycle

[0019] Further, the tool change time period and the blackout period are manually set time periods.

[0020] The present invention also provides an intelligent tool change system, which is characterized in that it includes an MDC system, a TLM system and an MES system;

[0021] The MDC system is used to obtain the real-time life of all tools on each production line and each machine tool in real time;

[0022] During the tool change time period, the TLM system is used to calculate the remaining life of the corresponding tool according to the real-time life. If the remaining life is lower than the set warning life value, a warning is issued and the corresponding tool is marked with a first warning mark; at the same time, the remaining life of each tool is converted into the remaining processing time. When the remaining processing time is less than the set value of the continuous operation time of its production line during the tool change time period, the tool is marked with a second warning mark; then tool change information is generated: when replacing the tool marked with the first warning mark, the tool marked with the second warning mark also needs to be replaced;

[0023] When entering the black light time period, the TLM system is used to calculate the remaining life of the corresponding tool according to the real-time life within the set time before entering the black light time period; the remaining life of each tool is converted into the remaining processing time. When the remaining processing time is less than the set value of the continuous operation time of the production line during the black light time period, a warning is issued and the corresponding tool is marked with a first warning mark before entering the black light time period, and tool change information is generated to remind the worker to change the tool;

[0024] The MES system is used to receive the tool change information sent by the TLM system and send the tool change information to the site to guide the worker to change the tool.

[0025] The present invention also provides a computer storage medium storing a computer program, which is characterized in that when the computer program is executed in a processor, the above-mentioned intelligent tool change method is executed.

[0026] The beneficial effects of the present invention are:

[0027] 1. By setting the tool change time period and the black light time period, the present invention judges the size of the remaining processing time of the tool and the continuous operation time of the production line during the tool change time period within the tool change time period, and replaces the tool with the remaining processing time less than the continuous operation time of the production line during the tool change time period while replacing the tool with the remaining life lower than the set warning life value; in addition, before entering the black light time period, replace the tool with the remaining processing time less than the continuous operation time of the production line during the black light time period; the present invention centrally replaces the tools within the tool change time period, reduces the tool change frequency, improves the production line start-up rate, makes the tool change time period and the continuous operation time flexibly controllable, and meets the needs of the unmanned chemical plant. Such an intelligent tool change strategy plays an important role in the TLM (Tool Management System).

[0028] 2. The present invention can complete the tool replacement for multiple production lines, identify the tool replacement conflicts in the production lines, and intelligently avoid them by adjusting the tool replacement time, enabling fewer people to manage more production lines. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a flowchart of the intelligent tool replacement method in the embodiment. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0030] To make the above objects, features, and advantages of the present invention more obvious and understandable, the following detailed description of the specific embodiments of the present invention is made in conjunction with the accompanying drawings of the specification. Obviously, the described embodiments are some but not all of the embodiments of the present invention. Many specific details are set forth in the following description to facilitate a full understanding of the present invention, but the present invention can also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the connotation of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed below.

[0031] In the construction of a digital factory, the TLM (Tooling and Tool Management System) obtains the tool BOM list (Bill of Materials), and the BOM list includes the product numbers to be processed by the tool, the rated life of the tool, the tool setting length, the spindle speed feed, etc.; the remaining life of the tool on the machine tool is monitored in real time through the MDC (Manufacturing Data and Process Collection System in the Workshop); the production line structure tree is obtained through the MES, including the machine tool type, quantity, etc.

[0032] Before performing the intelligent tool replacement operation in this embodiment, the production line needs to be set up. First, the operation time period of the production line is divided into a tool replacement time period and a blackout time period. The tool replacement time period refers to the time when there are workers in the workshop who can perform tool replacement at any time. The blackout time period refers to the time when there are no workers or only a few on-duty personnel in the workshop, and completely unmanned blackout production is carried out. During this time period, there should be no tool life warning. The tool replacement time period and the blackout time period can be set manually by the user, and there can be multiple tool replacement time periods or blackout time periods in a day. Secondly, the continuous operation time of the production line is set. Since there are workers on-site during the tool replacement time period, the continuous operation time of the production line can be shorter, which can improve the tool utilization rate; the continuous operation time during the blackout time period is the blackout time period.

[0033] Combined with Figure 1 , the intelligent tool replacement method of this embodiment is described in detail:

[0034] Obtain the real-time life of the tool. Combining with the product cutting time, within the set tool replacement time period, calculate the remaining life of all tools in all production lines according to the real-time life. If the remaining life is lower than the set warning life value, a warning is issued and the corresponding tool is marked with a first warning mark, such as a red mark, to remind the worker to replace this tool;

[0035] Meanwhile, convert the remaining life of the rest of the tools in all production lines into remaining processing time. When the remaining processing time is less than the continuous operation time of the production line during the tool change period, that is, it is necessary to ensure that no tool life expires during this period, and mark the corresponding tool with a second warning mark, which can be a yellow mark; remaining processing time = remaining life (pieces) × workpiece beat;

[0036] According to the first warning mark and the second warning mark, sort the tools according to the urgency of tool change to generate tool change information, and send the tool change information to the site to guide workers to change tools; The tools marked in red must be replaced before the remaining life reaches 0. When replacing the tools with red warnings, it is also necessary to replace the tools marked in yellow (the life has not reached the warning value, but it is not enough to complete the processing of the continuous operation time) at the same time. In this way, during the tool change period of the production line, the tools with remaining life lower than the warning life value and the remaining life less than the continuous operation time of the production line can be replaced together, so as to realize centralized tool change and reduce the tool change frequency of the production line. The tool change situation will be sent to the MOP machine display screen by the TLM system through the MES to guide workers to change tools. The specific process can be executed as follows:

[0037] Judge the urgency of tool change for each tool in each machine tool according to the first warning mark and the second warning mark, and sort the tools in each machine tool according to the urgency of tool change;

[0038] Judge the urgency of tool change for each machine tool in each production line according to the first warning mark and the second warning mark, and sort the machine tools in each production line according to the urgency of tool change;

[0039] Judge the urgency of tool change for each production line according to the first warning mark and the second warning mark, and sort each production line according to the urgency of tool change;

[0040] Dynamically display the estimated tool change time of each production line. If there is a conflict in the tool change time, advance the production line that triggers the tool change warning by one time period. Otherwise, generate tool change information according to the production line order, the order of machine tools in the production line, and the order of tools on the machine tool, and send the tool change information to the site to guide workers to change all tools with a life less than N in each production line, where N is the set value of the continuous operation time of the production line.

[0041] When entering the black light period, the system needs to calculate the remaining life of the tools on all production lines, and convert it into the remaining processing time according to the workpiece beat, that is, the remaining life. When the remaining processing time is less than the set value of the continuous operation time of the production line during the black light period, the system issues a warning half an hour before entering the black light period (the advance time can be freely set according to the actual situation), and indicates the first warning mark, such as red display, to remind workers to change tools. Thus, it ensures the continuous operation of the factory production line without personnel.

[0042] As Figure 1 shown, the above method can be implemented based on the MDC system, the TLM system, and the MES system. The MDC system is used to obtain the real-time life of all tools on each production line and each machine tool in real time; during the tool change time period, the TLM system is used to calculate the remaining life of the corresponding tool according to the real-time life. If the remaining life is lower than the set warning life value, a warning is issued and the corresponding tool is marked with a first warning mark; at the same time, the remaining life of each tool is converted into the remaining processing time. When the remaining processing time is less than the set value of the continuous operation time of its production line during the tool change time period, the tool is marked with a second warning mark; then, tool change information is generated: when replacing the tool marked with the first warning mark, the tool marked with the second warning mark also needs to be replaced; when entering the blackout time period, the TLM system is used to calculate the remaining life of the corresponding tool according to the real-time life within the set time before entering the blackout time period; the remaining life of each tool is converted into the remaining processing time. When the remaining processing time is less than the set value of the continuous operation time of the production line during the blackout time period, a warning is issued and the corresponding tool is marked with a first warning mark before entering the blackout time period, and tool change information is generated to remind the worker to change the tool; the MES system is used to receive the tool change information sent by the TLM system and send the tool change information to the site to guide the worker to change the tool.

[0043] This embodiment can also provide a computer-readable storage medium for storing a program that, when executed, implements the steps of the intelligent tool change method. In some possible implementation manners, the present invention can also be implemented in the form of a program product, which includes program code. When the program product runs on a terminal device, the program code is used to cause the terminal device to execute the steps according to various exemplary embodiments of the present invention described in the foregoing method section of this specification. For the program product for implementing the above method, it can use a portable compact disc read-only memory (CD-ROM) and include program code, and can run on a terminal device, such as a personal computer. However, the program product of the present invention is not limited thereto. In the present invention, the computer-readable storage medium can be any tangible medium that contains or stores a program, and this program can be used by or combined with an instruction execution system, apparatus, or device. The program product can adopt any combination of one or more readable media. The readable media can be a readable signal medium or a readable storage medium. The readable storage medium can be, for example, but not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination of the above. More specific examples (non-exhaustive list) of the readable storage medium include: an electrical connection having one or more wires, a portable disk, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the above.

Claims

1. An intelligent tool changing method, characterized in that, Obtain the real-time life of all tools on each production line and each machine tool in real time; based on the real-time life, perform the following processes respectively during the tool change time period and the time period when entering the blackout period: Tool change time period: Step 1a: Calculate the remaining life of all tools according to the real-time life. If the remaining life is lower than the set warning life value, issue a warning and mark the corresponding tool with the first warning mark; At the same time, convert the remaining life of the other tools into remaining processing time. When the remaining processing time is less than the continuous operation time of its production line during the tool change time period, mark the corresponding tool with the second warning mark; Step 2a: According to the first warning mark and the second warning mark, sort the tools according to the urgency of tool change to generate tool change information, and send the tool change information to the site to guide the workers to change the tools. When changing the tool marked with the first warning mark, it is also necessary to change the tool marked with the second warning mark; Entering the blackout period: Step 1b: Calculate the remaining life of the corresponding tool according to the real-time life within the set time before entering the blackout period; Step 2b: Convert the remaining life of each tool into remaining processing time. When the remaining processing time is less than the continuous operation time of its production line during the blackout period, issue a warning and mark the corresponding tool with the first warning mark before entering the blackout period, generate tool change information, and send the tool change information to the site to guide the workers to change the tools; Among them, Step 2a is specifically: Step 2a1: Judge the urgency of tool change for each tool in each machine tool according to the first warning mark and the second warning mark, and sort the tools in each machine tool according to the urgency of tool change; Step 2a2: Judge the urgency of tool change for each machine tool in each production line according to the first warning mark and the second warning mark, and sort the machine tools in each production line according to the urgency of tool change; Step 2a3: Judge the urgency of tool change for each production line according to the first warning mark and the second warning mark, and sort each production line according to the urgency of tool change; Step 2a4: Dynamically display the estimated tool change time of each production line. If there is a conflict in the tool change time, advance the production line that triggers the tool change warning first by one time period. Otherwise, generate tool change information according to the production line order, the machine tool order within the production line, and the tool order on the machine tool, and send the tool change information to the site to guide the workers to change all tools with a life less than N in each production line, where N is the set value of the continuous operation time of the production line.

2. The intelligent tool change method according to claim 1, wherein: In Step 1a and Step 2b, the remaining tool life is converted into the remaining processing time through the following formula: Remaining processing time = remaining life (pieces) × workpiece beat.

3. The intelligent tool change method according to claim 2, wherein: The tool change time period and the time period when entering the blackout period are manually set time periods.

4. An intelligent tool changing system, characterized in that, Including the MDC system, TLM system and MES system; The MDC system is used to obtain the real-time life of all tools on each production line and each machine tool in real time; During the tool change time period, the TLM system is used to calculate the remaining life of the corresponding tool according to the real-time life. If the remaining life is lower than the set warning life value, a warning is issued and the corresponding tool is marked with a first warning mark. At the same time, the remaining life of each tool is converted into the remaining processing time. When the remaining processing time is less than the set value of the continuous running time of its production line during the tool change time period, the tool is marked with a second warning mark. Then, tool change information is generated: when replacing the tool marked with the first warning mark, the tool marked with the second warning mark also needs to be replaced. When entering the black light time period, the TLM system is used to calculate the remaining life of the corresponding tool according to the real-time life within the set time before entering the black light time period. The remaining life of each tool is converted into the remaining processing time. When the remaining processing time is less than the set value of the continuous running time of the production line during the black light time period, a warning is issued and the corresponding tool is marked with a first warning mark before entering the black light time period, and tool change information is generated to remind the worker to perform tool change. The MES system is used to receive the tool change information sent by the TLM system and send the tool change information to the site to guide the worker to perform tool change.

5. A computer storage medium stores a computer program, characterized in that, When the computer program is executed in the processor, it executes the steps of the intelligent tool change method according to any one of claims 1-3.

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