A numerical control equipment management control system and method

Abstract

A numerical control equipment management control system and method, including cutting equipment and servo motors of each numerical control axis of the equipment, the cutting equipment includes at least three linear motion axes constituting a three-coordinate system, and a main motion axis of a cutter head rotation for cutting, the three linear motion axes are defined as X, Y and Z axes respectively, the main motion axis of the cutter head rotation is defined as SP axis, the three linear motion axes and the main motion axis of the cutter head rotation all use servo motors, displacement sensors for detecting displacement are provided on the X, Y and Z axes, and a speed sensor for detecting speed is provided on the SP axis, so that technicians, relevant business managers and operators can fully and systematically understand and grasp the actual processing and operation of numerical control equipment. The user terminal automatically improves and adjusts the cutting processing parameters of each process step through analysis, gives full play to the rated capacity of the equipment, increases the direct cutting weight, and realizes high-quality, safe and efficient mechanical processing.

Description

Technical Field

[0001] The present invention relates to the technical field of numerical control equipment communication control, and in particular to a numerical control equipment management control system and method. Background Art

[0002] At present, the control method of the numerical control equipment management system (DNC) is mainly through the technicians programming, determining the processing parameters, the operators clamping the workpiece, downloading the program, and processing the workpiece through the numerical control equipment. The numerical control equipment management system (DNC) control device is mainly composed of equipment, sensors, numerical control equipment controllers, workstations, management system servers, user terminals and networks. The numerical control equipment management system (DNC) collects information, processes information and provides feedback. The main key information KPIs provided by the existing feedback are:

[0003] 1) Shift time (A): the duration from the start of a production shift to the end of the shift;

[0004] 2) Processing time (B): The processing time is based on the time of collecting the machine tool NC usage signal;

[0005] 3) Failure time (C): The downtime of a single machine tool caused by a failure during a production shift (if the downtime duration of the failure exceeds the set time according to the alarm, it is considered a failure, and if the alarm duration is less than the set time, it is not considered a failure);

[0006] 4) Idle time (D): the time during a production shift when the equipment is idle, not malfunctioning and not processing;

[0007] 5) Power-off disconnection time (E): the time when the device is not powered on or the connection is disconnected;

[0008] 6) Number of fault shutdowns (F): The number of faults that occur on a single machine tool during a production shift (if the duration of the fault shutdown exceeds the set time, it is considered a fault, and if the duration is less than the set time, it is not considered a fault);

[0009] 7) Number of accidents (G): The frequency of occurrence is extremely low, generally involving processing collisions and other types, and is counted as an accident (violation of operating procedures, and the data needs to be manually entered);

[0010] 8) Equipment utilization rate: =(processing time / shift time) × 100% = (B / A) × 100%;

[0011] 9) Equipment operating rate: = (processing time + failure time + idle time) / shift time × 100% = (B + C + D) / A × 100%;

[0012] 10) Equipment failure rate (F): = failure time / (failure time+processing time) × 100% = C / (C+B) × 100%;

[0013] 11) Mean maintenance time MTTR: ​​= failure time / number of failures = C / F;

[0014] 12) Equipment failure interval time MTBF: = (shift time - failure time) / number of failures = (AC) / F.

[0015] At present, the information provided by these feedbacks mainly reflects the time utilization of CNC equipment, and there are some shortcomings: first, technical personnel and relevant business management personnel only know the time utilization of CNC equipment and the operation of process parameters in the three directions of XYZ, but cannot directly know the actual cutting volume or cutting weight of the equipment in depth; second, technical personnel, relevant business management personnel and operators do not know the corresponding actual load power, rated power and motor load rate of the motor under the operation of processing parameters; third, due to not knowing the above-mentioned situation, technical personnel, relevant business management personnel and operators cannot analyze and improve the processing parameters in a targeted manner, and cannot increase the actual cutting weight, give full play to the capabilities of CNC equipment and improve cutting efficiency while ensuring processing quality and preventing tool damage and equipment overload. Summary of the invention

[0016] The technical problem to be solved by the present invention is to provide a numerical control equipment management control system and method, which can centrally manage and read data of cutting equipment in a processing workshop, and make processing adjustments according to the equipment status.

[0017] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0018] A numerical control equipment management and control system includes a cutting device and servo motors for each numerical control axis of the device. The cutting device includes at least three linear motion axes forming a three-coordinate system and a main motion axis of a cutter head for cutting. The three linear motion axes are defined as X, Y and Z axes respectively, and the main motion axis of the cutter head is defined as an SP axis. The three linear motion axes and the main motion axis of the cutter head all use servo motors. Displacement sensors for detecting displacement are provided on the X, Y and Z axes, and a speed sensor for detecting speed is provided on the SP axis. The servo motor, the displacement sensor and the speed sensor are connected to a motor drive. The motor drive reads the displacement data of the X, Y and Z axes and the speed data of the SP axis, and calculates the current power of each motor according to the current motor speed and torque. The motor drive is connected to a controller of a numerical control system in communication. An operation display is provided at the cutting device end. The numerical control system controllers of multiple cutting devices are connected to a switch in communication. The switch is connected to a device management DNC ​​server in communication. The switch is connected to multiple user terminals at a remote end in communication.

[0019] At the above-mentioned user terminal, the technical staff sets the workpiece material, blank size, blank weight, machining margin, form and position tolerance requirements, allowable tool temperature, power safety factor, allowable machine vibration value and tool parameters of the specified cutting equipment, and compiles the machining program and determines the machining parameters of each step in the program. The set parameters and programs are uploaded to the equipment management DNC ​​server. The CNC system controller of each cutting equipment reads the set parameters and programs in the equipment management DNC ​​server according to the operation of the equipment operator and performs machining and cutting. The motor drive reads the torque and displacement data of the linear axis, the torque and speed data of the SP axis and the current power of the CNC axis during the cutting process and uploads them to the user terminal.

[0020] The user terminal calculates the idle torque of the spindle when it is not in contact with the workpiece at each step in the machining program according to the blank size and weight of the specified cutting equipment and the machining parameters in the machining program, and compares the current torque of each axis detected every other week with the calculated idle torque to determine whether the spindle has contacted the workpiece to start cutting. If the current torque is greater than the calculated idle torque, it is determined that the spindle has contacted the workpiece at this time, which is used as the machining inspiration time for this step, and the displacement data and tool parameters of each axis starting from this time are recorded, and calculated and converted into cutting volume, cutting weight and compliance rate of each motor.

[0021] When the above-mentioned cutting equipment is a CNC gantry milling machine, there are:

[0022] Cutting volume of CNC gantry milling machine (mm 3 / min) = cutting depth (Z) mm * [cutting width (Y) mm or cutter head diameter mm] * feed speed (X) mm / min

[0023] Cutting volume of CNC gantry milling machine (dm 3 / min)=1 / 1000000*cutting depth (Z) mm*[cutting width (Y) mm or cutter head diameter (mm]*feed speed (X) mm / min

[0024] Cutting weight of CNC gantry milling machine (Kg / min) = 1 / 1000000* cutting depth (Z) mm* [cutting width (Y) mm or cutter head diameter mm]* feed speed (X) mm / min* material specific gravity Kg / dm 3

[0025] Motor load rate (%) = motor actual power Kw / motor rated power Kw*100%

[0026] Using the above-mentioned control management method of a numerical control equipment management control system, the specific steps are:

[0027] Step 1: The technicians first select the tool, determine the tool setting point, compile the NC program, and determine the processing parameters of each step on the user terminal according to the material of the workpiece, processing margin, geometric tolerance requirements, tool allowable temperature, power safety factor, machine vibration allowable value and machine characteristic parameter requirements. The processing parameters include cutting depth (Z) mm, cutting width (Y) mm or cutter head diameter (mm), feed speed (X) mm / min, and consider the number of blades on the cutter head N, and the spindle speed of the cutter head n / min. After simulation and review, upload to the equipment management DNC ​​server;

[0028] Step 2: The operator receives the work assignment, the clamping process of the workpiece, the version number of the NC program, the tool and tool setting requirements on the workstation, downloads the NC program to the CNC system controller of the cutting equipment, clamps the workpiece, finds the tool setting point, and starts the program for machining and cutting;

[0029] Step 3: During the operation of the cutting equipment, the CNC system controller reads the displacement data of each linear axis, the speed data of the SP axis and the current power of each motor, and sends the data to the equipment management DNC ​​server to calculate the cutting volume (mm 3 / min), cutting weight (Kg / min), related motor load rate (%), and cutting volume (mm) can be viewed in real time on the user terminal. 3 / min) or cutting weight (Kg / min), each motor load rate (%), workpiece and tool temperature information, and historical information can also be viewed;

[0030] Step 4: The user terminal reads the cutting weight, the comparison information of the motor load rate related to the processing, and the quality of the actual processed part, and compares them with the set load parameters to determine whether the equipment is currently in a small load operation state or a full load operation state. In combination with the surface quality and the geometric tolerance quality of the processed part and the processing time requirements, the cutting parameters of each step of the processing program are adjusted and transmitted to the cutting equipment. The operator can choose to continue processing with the current parameters or the optimized parameters.

[0031] The present invention provides a numerical control equipment management control system and method. In the development and design of numerical control equipment management system (DNC), the data acquisition logic and algorithm are determined, the cutting volume, cutting weight, motor load rate are calculated, and the cutting volume (mm) is fed back on the network terminal application software interface. 3 / min), cutting weight (Kg / min), relevant motor real-time load power, rated power and motor load rate (%), workpiece and tool temperature, etc. This allows technicians, relevant business managers and operators to fully and systematically understand and grasp the actual processing and operation of CNC equipment. The user terminal can adjust the cutting parameters of each step through targeted analysis and improvement, give full play to the rated capacity of the equipment, increase the direct cutting weight, and achieve high-quality, safe and efficient mechanical processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The present invention will be further described below in conjunction with the accompanying drawings and embodiments:

[0033] Figure 1 It is a schematic diagram of the structure of the cutting management and control system of the numerical control equipment of the present invention. DETAILED DESCRIPTION

[0034] The technical solution of the present invention is described in detail below in conjunction with the accompanying drawings and embodiments.

[0035] like Figure 1 As shown in, a numerical control equipment management and control system includes a cutting device and servo motors for each numerical control axis of the device, the cutting device includes at least three linear motion axes forming a three-coordinate system, and a main motion axis of a cutter disc rotation for cutting, the three linear motion axes are defined as X, Y and Z axes respectively, the main motion axis of the cutter disc rotation is defined as the SP axis, the three linear motion axes and the main motion axis of the cutter disc rotation all use servo motors, displacement sensors for detecting displacement are provided on the X, Y and Z axes, a speed sensor for detecting speed is provided on the SP axis, the servo motor, the displacement sensor and the speed sensor are connected to the motor drive, the motor drive reads the displacement data of the X, Y and Z axes and the speed data of the SP axis, and calculates the current power of each motor according to the current motor speed and torque, the motor drive is communicatively connected to the controller of the numerical control system, an operation display is provided at the cutting device end, the numerical control system controllers of multiple cutting devices are communicatively connected to the switch, the switch is communicatively connected to the equipment management DNC ​​server, and the switch is communicatively connected to multiple user terminals at the remote end.

[0036] The torque of the motor can be calculated by the motor driver based on the current driving current of the motor.

[0037] Management software development and design personnel compile management software for CNC equipment management system, determine the data acquisition logic and algorithm of CNC equipment cutting volume, cutting weight and actual motor load rate, and design a visual interface for real-time feedback of cutting volume, cutting weight, actual load power of related motors, rated power and motor load rate; processing programming technicians select tools, determine tool setting points, compile processing programs, and determine processing parameters for each process step (cutting depth (Z) mm, cutting width (Y) mm (or cutter head diameter mm), feed speed (X) mm / min (comprehensively consider the number of blades on the cutter head N), spindle cutter head speed n / min) on the user terminal according to the material of the workpiece, processing margin, geometric tolerance requirements, allowable tool temperature, power safety factor, allowable value of machine tool vibration and machine tool performance parameters. The operator installs and adjusts the workpiece, finds the tool setting points, and starts the program for processing and cutting; the management system collects and processes the information fed back by the CNC system, calculates and issues the cutting volume (mm 3 / min), cutting weight (Kg / min), relevant motor load rate (%), workpiece and tool temperature and other information; technical personnel and relevant business management personnel can see it in real time on the user terminal, and can analyze, improve and adjust the cutting processing parameters of each step, conduct process test verification, and give full play to the capacity of the equipment while ensuring quality and equipment safety, and appropriately increase the cutting volume (mm 3 / min), cutting weight (Kg / min) and related motor load rate (%), so as to achieve the goal of high-quality, safe and efficient machining and cutting of CNC equipment.

[0038] At the above-mentioned user terminal, the technical staff sets the workpiece material, blank size, blank weight, machining margin, form and position tolerance requirements, allowable tool temperature, power safety factor, allowable machine vibration value and tool parameters of the specified cutting equipment, and compiles the machining program and determines the machining parameters of each step in the program. The set parameters and programs are uploaded to the equipment management DNC ​​server. The CNC system controller of each cutting equipment reads the set parameters and programs in the equipment management DNC ​​server according to the operation of the equipment operator and performs machining and cutting. The motor drive reads the torque and displacement data of the linear axis, the torque and speed data of the SP axis and the current power of the CNC axis during the cutting process and uploads them to the user terminal.

[0039] The above-mentioned user terminal calculates the calculated idle torque when the spindle does not contact the workpiece during each step in the processing program based on the blank size and weight of the specified cutting equipment, combined with the processing parameters in the processing program, and compares the current torque of each axis detected every other week with the calculated idle torque to determine whether the spindle contacts the workpiece to start cutting. If the current torque is greater than the calculated idle torque, it is determined that the spindle has contacted the workpiece at this time, which is used as the processing inspiration time for this step, and the displacement data and tool parameters of each axis starting from this time are recorded, and calculated and converted into cutting volume, cutting weight and each motor load rate.

[0040] When the above-mentioned cutting equipment is a CNC gantry milling machine, there are:

[0041] Cutting volume of CNC gantry milling machine (mm 3 / min) = cutting depth (Z) mm * [cutting width (Y) mm or cutter head diameter mm] * feed speed (X) mm / min

[0042] Cutting volume of CNC gantry milling machine (dm 3 / min)=1 / 1000000*cutting depth (Z) mm*[cutting width (Y) mm or cutter head diameter (mm]*feed speed (X) mm / min

[0043] Cutting weight of CNC gantry milling machine (Kg / min) = 1 / 1000000* cutting depth (Z) mm* [cutting width (Y) mm or cutter head diameter mm]* feed speed (X) mm / min* material specific gravity Kg / dm 3

[0044] Motor load rate (%) = motor actual power Kw / motor rated power Kw*100%

[0045] Using the above-mentioned control management method of a numerical control equipment management control system, the specific steps are:

[0046] Step 1: The technicians first select the tool, determine the tool setting point, compile the NC program, and determine the processing parameters of each step on the user terminal according to the material of the workpiece, processing margin, geometric tolerance requirements, tool allowable temperature, power safety factor, machine vibration allowable value and machine characteristic parameter requirements. The processing parameters include cutting depth (Z) mm, cutting width (Y) mm or cutter head diameter (mm), feed speed (X) mm / min, and consider the number of blades on the cutter head N, and the spindle speed of the cutter head n / min. After simulation and review, upload to the equipment management DNC ​​server;

[0047] Step 2: The operator receives the work assignment, the clamping process of the workpiece, the version number of the NC program, the tool and tool setting requirements on the workstation, downloads the NC program to the CNC system controller of the cutting equipment, clamps the workpiece, finds the tool setting point, and starts the program for machining and cutting;

[0048] Step 3: During the operation of the cutting equipment, the CNC system controller reads the displacement data of each linear axis, the speed data of the SP axis and the current power of each motor, and sends the data to the equipment management DNC ​​server to calculate the cutting volume (mm 3 / min), cutting weight (Kg / min), related motor load rate (%), and cutting volume (mm) can be viewed in real time on the user terminal. 3 / min) or cutting weight (Kg / min), motor load rate (%), workpiece and tool temperature information, and historical information can also be viewed;

[0049] Step 4: The user terminal reads the cutting weight, the comparison information of the motor load rate related to the processing, and the quality of the actual processed part, and compares them with the set load parameters to determine whether the equipment is currently in a small load operation state or a full load operation state. In combination with the surface quality and the geometric tolerance quality of the processed part and the processing time requirements, the cutting parameters of each step of the processing program are adjusted and transmitted to the cutting equipment. The operator can choose to continue processing with the current parameters or the optimized parameters.

Claims

1. A numerical control equipment management and control system, comprising a cutting device and servo motors for each numerical control axis of the device, characterized in that: The cutting equipment includes at least three linear motion axes constituting a three-coordinate system and a main motion axis of a cutter head for cutting. The three linear motion axes are defined as X, Y and Z axes respectively, and the main motion axis of the cutter head is defined as an SP axis. The three linear motion axes and the main motion axis of the cutter head all use servo motors. Displacement sensors for detecting displacement are provided on the X, Y and Z axes, and a speed sensor for detecting speed is provided on the SP axis. The servo motor, the displacement sensor and the speed sensor are connected to a motor drive. The motor drive reads displacement data of the X, Y and Z axes and speed data of the SP axis, and calculates the current power of each motor according to the current motor speed and torque. The motor drive is connected to the controller of the numerical control system in communication. An operation display is provided at the cutting equipment end. The numerical control system controllers of multiple cutting equipment are connected to a switch in communication. The switch is connected to a device management DNC ​​server in communication. The switch is connected to multiple user terminals at the remote end in communication. At the user terminal, the technician sets the workpiece material, blank size, blank weight, machining margin, geometric tolerance requirements, tool allowable temperature, power safety factor, machine vibration allowable value and tool parameters of the specified cutting equipment, and compiles the machining program and determines the machining parameters of each step in the program. The set parameters and program are uploaded to the equipment management DNC ​​server. The CNC system controller of each cutting equipment reads the set parameters and program in the equipment management DNC ​​server according to the operation of the equipment operator and performs machining and cutting. The motor drive reads the torque and displacement data of the linear axis, the torque and speed data of the SP axis and the current power of the CNC axis during the cutting process and uploads them to the user terminal. The user terminal calculates the calculated idle torque when the spindle does not contact the workpiece in each step of the processing program according to the blank size and blank weight of the specified cutting equipment and the processing parameters in the processing program, and compares the current torque of each axis detected in the processing process with the calculated idle torque to determine whether the spindle contacts the workpiece to start cutting. If the current torque is greater than the calculated idle torque, it is determined that the spindle has contacted the workpiece at this time, which is used as the processing revelation time of this step, and the displacement data and tool parameters of each axis starting from this time are recorded, and the calculation is converted into cutting volume, cutting weight and compliance rate of each motor; When the cutting equipment is a CNC gantry milling machine, it has: Cutting volume of CNC gantry milling machine mm 3 / min=cutting depth Zmm*[cutting width Ymm or cutter head diameter mm]*feed speed Xmm / min Cutting volume dm of CNC gantry milling machine 3 / min=1 / 1000000*cutting depth Zmm*[cutting width Ymm or cutter head diameter mm]*feed speed Xmm / min Cutting weight of CNC gantry milling machine Kg / min=1 / 1000000*cutting depth Zmm*[cutting width Ymm or cutter diameter mm]*feed speed Xmm / min*material specific gravity Kg / dm 3 Motor load rate (%) = motor actual power Kw / motor rated power Kw*100%.

2. A control management method using a numerical control equipment management control system according to claim 1, characterized in that: The specific steps are: Step 1: The technicians first select the tool, determine the tool setting point, compile the NC program, and determine the processing parameters of each process step on the user terminal according to the material of the workpiece, processing margin, geometric tolerance requirements, tool allowable temperature, power safety factor, machine vibration allowable value and machine characteristic parameter requirements. The processing parameters include cutting depth Zmm, cutting width Ymm or cutter head diameter mm, feed speed Xmm / min, and consider the number of blades N on the cutter head and the spindle speed n / min of the cutter head. After simulation and review, upload to the equipment management DNC ​​server; Step 2: The operator receives the work assignment, the clamping process of the workpiece, the version number of the NC program, the tool and tool setting requirements on the workstation, downloads the NC program to the CNC system controller of the cutting equipment, clamps the workpiece, finds the tool setting point, and starts the program for machining and cutting; Step 3: During the operation of the cutting equipment, the CNC system controller reads the displacement data of each linear axis, the speed data of the SP axis and the current power of each motor, and sends the data to the equipment management DNC ​​server to calculate the cutting volume mm 3 / min, cutting weight Kg / min, relevant motor load rate (%), and cutting volume mm can be viewed in real time on the user terminal. 3 / min or cutting weight Kg / min, each motor load rate (%), workpiece and tool temperature information, and historical information can also be viewed; Step 4: The user terminal reads the cutting weight, the comparison information of the motor load rate related to the processing, and the quality of the actual processed part, and compares them with the set load parameters to determine whether the equipment is currently in a small load operation state or a full load operation state. In combination with the surface quality and the geometric tolerance quality of the processed part and the processing time requirements, the cutting parameters of each step of the processing program are adjusted and transmitted to the cutting equipment. The operator can choose to continue processing with the current parameters or the optimized parameters.

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