A multi-sensor integrated intelligent tool holder real-time monitoring and anti-collision system

Abstract

A multi-sensor integrated intelligent tool holder real-time monitoring and anti-collision system, comprising: an intelligent tool holder device, an external PLC controller, a built-in relay, a numerical control machine tool and a PC signal processing and display module; the intelligent tool holder device comprises: a handle cone structure, a force sensor structure, a resistance strain gauge group, a protective shell, a plurality of supporting copper columns, a first hardware circuit board, a second hardware circuit board, a vibration sensor, a lithium battery, a fixed upper shell, a fixed bottom shell, a draw stud, a clasp spring, a compression cap and an end mill. The application is based on the collected cutting signals for real-time analysis and rapid judgment and response, is not affected by the machining environment and the shape and size of the workpiece, is accurate in measurement, greatly reduces the influence of the external sensor arrangement distance on the cutting data accuracy, and is suitable for the monitoring of cutting force and vibration and the anti-collision monitoring link in the part machining process, and improves the cutting automation, intelligence and safety level.

Description

Technical Field

[0001] This invention relates to the field of intelligent equipment monitoring technology in machining, specifically to an intelligent tool holder real-time monitoring and anti-collision system integrating multiple sensors. Background Technology

[0002] Cutting data monitoring and collision avoidance technologies during machining are crucial development directions for achieving safe, automated, and intelligent machining in CNC machine tools. Accidental collisions and tool breakage in CNC machine tools are significant causes of prolonged machine downtime, reduced machining quality, and decreased efficiency. Damage to CNC machine tools can result in severe economic losses for enterprises and impact their research and production. In actual machining processes, limited human reaction time often prevents timely and effective intervention. Currently, there are two main technical approaches to effectively avoid machine tool collisions, reduce collision losses, and achieve collision protection: one is CNC system collision avoidance technology, and the other is CNC machine tool collision protection technology.

[0003] Collision avoidance technology in CNC systems primarily involves comprehensively constructing a digital environment within the CNC system that simulates the actual machining process. This allows for real-time monitoring of the spatial positions of machine tool components, fixtures, cutting tools, and jigs, preventing collisions during machine operation and improving operational safety. However, building this digital environment requires not only a digital model of the CNC machine tool itself but also digital models of commonly used cutting tools, jigs, and fixtures, making the use of this function challenging and cumbersome.

[0004] CNC machine tool collision protection technology primarily employs external sensors, such as current sensors, torque sensors, and vibration sensors, to detect changes in data during machine tool collisions or tool breakage. By using data boundary thresholds and appropriate algorithms, it determines the collision and tool breakage situation and sends a command to bring the machine to an emergency stop. CNC machine tool collision protection technology using vibration and force sensors has no specific configuration requirements for the CNC system itself; it can be used directly after installation and debugging, making its functionality relatively simple. However, traditional methods mainly place force or vibration sensors on the spindle box or worktable, with the monitoring position far from the collision area, making it difficult to accurately and efficiently collect collision signals, and the monitoring signal is singular. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent real-time monitoring and anti-collision system for tool holders that integrates multiple sensors. This system overcomes the limitations of traditional anti-collision sensors, which are often placed far apart and have only one type of collision signal, making it impossible to fully identify collision information during machining. It enables real-time wireless monitoring of the three-dimensional cutting force and three-dimensional vibration experienced by the tool in complex machining environments such as dry milling, while simultaneously achieving tool collision safety monitoring.

[0006] The technical solution adopted to achieve the purpose of this invention is as follows: a multi-sensor integrated intelligent tool holder real-time monitoring and anti-collision system, comprising: an intelligent tool holder device, an external PLC controller, a built-in relay, a machine tool system, and a PC-side signal processing and display module.

[0007] The intelligent tool holder device includes: a shank taper structure, a force sensor structure, a resistive strain gauge assembly, a protective shell, several supporting copper pillars, a first hardware circuit board, a second hardware circuit board, a vibration sensor, a lithium battery, a fixed upper shell, a fixed lower shell, a pull stud, a retaining ring, a pressure cap, and an end mill.

[0008] The shank cone structure is a cone with its top end cut off, and the lower end of the shank cone structure has three outward extension blocks.

[0009] A first groove is provided between the second extension block and the third extension block of the shank cone structure.

[0010] The top of the inner side of the first groove of the shank cone structure is provided with a first screw hole.

[0011] The second extension block of the shank tapered structure is provided with a plurality of second screw holes, which are parallel to the axial direction of the shank tapered structure.

[0012] The third extension block of the shank cone structure is provided with several first through holes.

[0013] The bottom of the shank cone structure has an inward opening.

[0014] The third extension block of the shank cone structure is provided with several sixth screw holes.

[0015] The force sensor structure is a cylinder, and the side of the force sensor structure is provided with several second grooves, and the second grooves are provided with I-shaped support columns.

[0016] The force sensor structure has an extension block extending outward at its lower end. The extension block at the lower end of the force sensor structure has threads on its outer side.

[0017] The top of the force sensor structure is provided with a third screw hole that matches the first through hole of the shank cone structure.

[0018] The force sensor structure has a second through hole at its center.

[0019] A third groove is provided at the upper end of the second through hole of the force sensor structure.

[0020] The force sensor structure has a fourth screw hole inwardly arranged in the third groove.

[0021] The protective shell is a cylindrical shell, and the top is provided with a third through hole that matches the second screw hole of the shank cone structure.

[0022] The first hardware circuit board includes two semi-circular circuit boards.

[0023] The first hardware circuit board has several fourth through holes.

[0024] The second hardware circuit board has several fifth through holes.

[0025] The fixed upper shell is provided with a sixth through hole.

[0026] The fixed bottom shell is provided with a seventh through hole that matches the sixth through hole of the fixed top shell.

[0027] The fixed bottom shell is provided with an eighth through hole.

[0028] The first through hole of the shank-tapered structure, the eighth through hole of the fixed base shell, and the third screw hole of the force sensor structure are fixedly connected by screws. The resistive strain gauge assembly is attached to the I-shaped support column of the force sensor structure, and the wires leading out from the resistive strain gauge assembly are connected to the first hardware circuit board. The third through hole of the protective shell and the second screw hole of the shank-tapered structure are fixedly connected by screws. The supporting copper column is fixedly connected to the first screw hole of the shank-tapered structure, and the fourth through hole of the first hardware circuit board and the supporting copper column are fixedly connected by screws. The fifth through hole of the second hardware circuit board and the fourth screw hole of the force sensor structure are connected by screws, and the second hardware circuit board is located in the third groove of the force sensor structure. The wires leading out from the second hardware circuit board are connected to the first hardware circuit board to realize power supply and data exchange. The vibration sensor is soldered to the second hardware circuit board, and the lithium battery is located between the fixed upper shell and the fixed base shell. The sixth through hole of the fixed upper shell, the seventh through hole of the fixed base shell, and the sixth screw hole of the shank-tapered structure are fixedly connected by screws. The fixed base shell is located on the third extension block of the shank-tapered structure. The pull stud is located inside the shank-tapered structure. The end mill is located inside the second through hole of the force sensor structure. The retaining ring is positioned between the end mill and the pressure cap. The pressure cap is threadedly fixed to the lower end of the force sensor structure.

[0029] The external PLC controller is connected to both the PC-side signal processing and display module and the built-in relay. Upon sensing a collision with the end mill, the PC-side signal processing and display module generates a collision signal and transmits it to the external PLC controller. The external PLC controller then controls the built-in relay, thereby achieving an emergency stop of the machine tool system. The PC-side signal processing and display module is connected to the intelligent tool holder device via Wi-Fi for data transmission and display.

[0030] When a collision occurs during milling, the end mill contacts the workpiece and receives a reaction cutting force. This cutting force is subsequently transmitted through the end mill and the retaining ring to the force sensor structure. The resistive strain gauge assembly attached to the force sensor structure and the vibration sensor soldered to the second hardware circuit board collect the corresponding signals and transmit them to the first hardware circuit board. After processing, the signals are wirelessly transmitted to the PC-side signal processing and display module for data display and collision detection. When a collision is detected, the PC-side signal processing and display module generates a collision signal and transmits it to the external PLC controller. The external PLC controller then controls the built-in relay to disconnect, thereby achieving an emergency stop of the machine tool system.

[0031] Furthermore, the resistance strain gauge group includes resistance strain gauges R1-R16.

[0032] The resistance strain gauges R1 to R4 form a Wheatstone bridge to measure the X-direction force.

[0033] The resistance strain gauges R5~R8 form a Wheatstone bridge to measure the Y-direction force.

[0034] The resistance strain gauges R9 to R16 form a Wheatstone bridge to measure the Z-axis force.

[0035] Furthermore, the third extension block of the shank cone structure is also provided with several wire outlet slots for routing the first hardware circuit board, the second hardware circuit board, the resistance strain gauge group, and the lithium battery.

[0036] Furthermore, the protective shell also has a power switch hole and a charging port hole on its side.

[0037] Furthermore, the first hardware circuit board includes a signal conditioning module and a data processing module.

[0038] The technical effects of this invention are undeniable. By using the cutting force and cutting vibration sensing functions of an intelligent tool holder device, this invention can monitor cutting data in real time and detect machine tool collisions by utilizing abnormal changes in cutting data during collisions and tool breakage, thereby controlling the machine tool to stop suddenly. Ultimately, this invention achieves real-time monitoring and intelligent anti-collision control of the cutting process.

[0039] The present invention discloses a multi-sensor integrated intelligent toolholder real-time monitoring and anti-collision system with a simple structure and layout. It simultaneously monitors tool cutting information during machining and achieves machine tool collision monitoring. Utilizing a monitoring-control loop composed of an intelligent toolholder device, an external PLC controller, built-in relays, and the machine tool system, it achieves rapid response to machine tool collisions, offering advantages such as strong adaptability and stable performance. The application of this device plays a positive role in improving the automation, intelligence, and safety of machining processes, yielding significant economic and social benefits.

[0040] The multi-sensor integrated intelligent real-time tool holder monitoring system of this invention can directly measure the cutting force and cutting vibration of the rotating tool, and analyze the collected cutting signals in real time to make rapid judgments and responses. It is unaffected by the processing environment and the shape and size of the workpiece, and the measurement is accurate. It greatly reduces the impact of the distance of the external sensor arrangement on the accuracy of the cutting data. This device is suitable for monitoring cutting force and vibration and anti-collision monitoring in the part processing process, improving the level of automation, intelligence and safety of cutting. Attached Figure Description

[0041] Figure 1 This is a block diagram of an intelligent tool holder real-time monitoring and anti-collision system;

[0042] Figure 2 This is an overall assembly drawing of the handle body for an intelligent tool holder device;

[0043] Figure 3 This is a structural diagram of the handle body of an intelligent tool holder device;

[0044] Figure 4 This is an overall cross-sectional view of the handle of the intelligent tool holder device;

[0045] Figure 5 This is a schematic diagram of the shank cone structure of the tool holder;

[0046] Figure 6 Figure (a) is a top view of the resistance strain gauge assembly, and Figure (b) is a bottom view of the resistance strain gauge assembly.

[0047] Figure 7 This is a schematic diagram of a Wheatstone bridge circuit for a resistive strain gauge assembly corresponding to a triaxial force.

[0048] Figure 8 This is a block diagram of the data acquisition circuit system of the intelligent tool holder device involved in this invention;

[0049] The figure shows the intelligent tool holder device 1, the shank cone structure 101, the first groove 1011, the first screw hole 10111, the second screw hole 1012, the first through hole 1013, the wire outlet groove 1014, the nail hole 1015, the opening 1016, the sixth screw hole 1017, the force sensor structure 102, the second groove 1021, the third screw hole 1022, the second through hole 1023, the third groove 1024, the fourth screw hole 1025, the resistance strain gauge assembly 103, the protective shell 104, the third through hole 1041, the power switch hole 1042, and the charging port. Hole 1043, several supporting copper pillars 105, fifth screw hole 1051, first hardware circuit board 106, fourth through hole 1061, second hardware circuit board 107, fifth through hole 1071, vibration sensor 108, lithium battery 109, fixed upper shell 110, sixth through hole 1101, fixed bottom shell 111, seventh through hole 1111, eighth through hole 1112, pull stud 112, snap ring 113, pressure cap 114, end mill 115, external PLC controller 2, built-in relay 3, machine tool system 4, PC-side signal processing and display module 5. Detailed Implementation

[0050] The present invention will be further described below with reference to embodiments, but it should not be construed that the scope of the present invention is limited to the following embodiments. Various substitutions and modifications made based on ordinary technical knowledge and common practices in the art without departing from the above-described technical concept of the present invention should be included within the scope of protection of the present invention.

[0051] Example 1:

[0052] See Figures 1 to 8 A multi-sensor integrated intelligent tool holder real-time monitoring and anti-collision system includes: an intelligent tool holder device 1, an external PLC controller 2, a built-in relay 3, a machine tool system 4, and a PC-side signal processing and display module 5.

[0053] The intelligent tool holder device 1 serves as the sensing unit and signal receiving and processing unit, the external PLC controller 2 serves as the control unit, and the built-in relay 3 and machine tool system 4 serve as the execution unit.

[0054] The intelligent tool holder device 1 includes: a shank cone structure 101, a force sensor structure 102, a resistance strain gauge group 103, a protective shell 104, several supporting copper pillars 105, a first hardware circuit board 106, a second hardware circuit board 107, a vibration sensor 108, a lithium battery 109, a fixed upper shell 110, a fixed bottom shell 111, a pull stud 112, a retaining ring 113, a pressure cap 114, and an end mill 115.

[0055] The shank cone structure 101 is a cone with its top end cut off, and the lower end of the shank cone structure 101 has three outward extension blocks.

[0056] A first groove 1011 is provided between the second extension block and the third extension block of the shank cone structure 101.

[0057] The top of the inner side of the first groove 1011 of the shank cone structure 101 is provided with a first screw hole 10111.

[0058] The second extension block of the shank tapered structure 101 is provided with a plurality of second screw holes 1012, the second screw holes 1012 being parallel to the axial direction of the shank tapered structure 101.

[0059] The third extension block of the shank cone structure 101 is provided with a plurality of first through holes 1013.

[0060] The top end of the shank cone structure 101 is provided with a nail hole 1015.

[0061] The bottom of the shank cone structure 101 has an inward opening 1016.

[0062] The third extension block of the shank cone structure 101 is provided with a plurality of sixth screw holes 1017.

[0063] The force sensor structure 102 is a cylinder, and the side of the force sensor structure 102 is provided with a plurality of second grooves 1021, and the second grooves 1021 are provided with I-shaped support columns.

[0064] The force sensor structure 102 has an extension block extending outward at its lower end. The extension block at the lower end of the force sensor structure 102 has threads on its outer side.

[0065] The top of the force sensor structure 102 is provided with a third screw hole 1022 that matches the first through hole 1013 of the shank cone structure 101.

[0066] The force sensor structure 102 has a second through hole 1023 at its center.

[0067] A third groove 1024 is provided at the upper end of the second through hole 1023 of the force sensor structure 102.

[0068] The force sensor structure 102 has a third groove 1024 with a fourth screw hole 1025 inwardly.

[0069] The protective shell 104 is a cylindrical shell, and the top is provided with a third through hole 1041 that matches the second screw hole 1012 of the shank cone structure 101.

[0070] The supporting copper column 105 is provided with external threads.

[0071] The bottom of the supporting copper column 105 is provided with a fifth screw hole 1051.

[0072] The first hardware circuit board 106 includes two semi-circular circuit boards.

[0073] The first hardware circuit board 106 is provided with a plurality of fourth through holes 1061.

[0074] The second hardware circuit board 107 is provided with a plurality of fifth through holes 1071.

[0075] The fixed upper shell 110 is provided with a sixth through hole 1101.

[0076] The fixed bottom shell 111 is provided with a seventh through hole 1111 that matches the sixth through hole 1101 of the fixed upper shell 110.

[0077] The fixed bottom shell 111 is provided with an eighth through hole 1112.

[0078] The first through hole 1013 of the shank-taper structure 101, the eighth through hole 1112 of the fixed base shell 111, and the third screw hole 1022 of the force sensor structure 102 are fixedly connected by screws. The resistive strain gauge assembly 103 is attached to the I-shaped support column of the force sensor structure 102, and the wires leading out from the resistive strain gauge assembly 103 are connected to the first hardware circuit board 106. The third through hole 1041 of the protective shell 104 and the second screw hole 1012 of the shank-taper structure 101 are fixedly connected by screws. The supporting copper column 105 is fixedly connected to the first screw hole 10111 of the shank-taper structure 101, and the fourth through hole 1061 of the first hardware circuit board 106 and the fifth screw hole 1051 of the supporting copper column 105 are fixedly connected by screws. The fifth through hole 1071 of the second hardware circuit board 107 and the fourth screw hole 1025 of the force sensor structure 102 are connected by screws. The second hardware circuit board 107 is located in the third groove 1024 of the force sensor structure 102. Wires leading from the second hardware circuit board 107 are connected to the first hardware circuit board 106 to achieve power supply and data exchange. The vibration sensor 108 is soldered to the second hardware circuit board 107, and the lithium battery 109 is located between the fixed upper shell 110 and the fixed bottom shell 111. The sixth through hole 1101 of the fixed upper shell 110, the seventh through hole 1111 of the fixed bottom shell 111, and the sixth screw hole 1017 of the shank tapered structure 101 are fixedly connected by screws. The fixed bottom shell 111 is located on the third extension block of the shank tapered structure 101. The pull stud 112 is located in the stud hole 1015 of the shank tapered structure 101. The end mill 115 is located in the second through hole 1023 of the force sensor structure 102. The retaining ring 113 is positioned between the end mill 115 and the pressure cap 114. The pressure cap 114 is threadedly fixed to the lower end of the force sensor structure 102.

[0079] The PC-side signal processing and display module 5 is connected to the external PLC controller 2 via a data cable. The built-in relay 3 is connected in series with the CNC panel and the hand-cranked emergency stop relay inside the machine tool system 4 and maintains the same normally closed state. The PLC controller 2 is connected to the built-in relay 3 via a data cable. By controlling the external PLC controller 2, the on / off control of the built-in relay 3 can be realized, thereby realizing the emergency stop control of the machine tool.

[0080] The external PLC controller 2 is connected to both the PC-side signal processing and display module 5 and the built-in relay 3. After sensing a collision with the end mill 115, the PC-side signal processing and display module 5 generates a collision signal and transmits it to the external PLC controller 2. The external PLC controller 2 then controls the built-in relay 3, thereby achieving an emergency stop of the machine tool system 4. The PC-side signal processing and display module 5 is connected to the intelligent tool holder device 1 via WIFI to achieve data transmission and display.

[0081] Before milling begins, the tool holder is powered via the Type-C charging port to ensure it has sufficient charge for operation. The operation and shutdown of the intelligent tool holder device's internal hardware circuitry are controlled by the power switch, which controls the on / off state of the lithium battery 109 within the tool holder.

[0082] When a collision occurs during milling, the end mill 115 comes into contact with the workpiece and is subjected to a reaction cutting force. This cutting force is successively transmitted to the force sensor structure 102 through the end mill 115 and the snap ring 113.

[0083] Radial forces in the X and Y directions and axial forces in the Z direction are generated on the strain gauge force sensor structure 102, causing slight deformation of the strain gauge force sensor structure 102. The resistance of the resistive strain gauge attached to the strain gauge force sensor structure 102 changes accordingly. After applying the excitation voltage U0, the corresponding three Wheatstone bridge generates millivolt voltage signals Ux, Uy and Uz and transmits them to the signal acquisition and conditioning module. When the tool contacts the workpiece, cutting vibration is generated and transmitted to the vibration sensor 108 on the second hardware circuit board 107 through the tool, snap ring 113 and strain gauge force sensor structure 102. The millivolt analog signal generated by the vibration sensor 108 is transmitted to the signal acquisition and conditioning module of the first hardware circuit board 106 through the external wire on the second hardware circuit board 107.

[0084] The resistive strain gauge assembly 103, attached to the force sensor structure 102, and the vibration sensor 108, soldered to the second hardware circuit board 107, collect corresponding signals and transmit them to the first hardware circuit board 106. After data processing such as amplification and filtering, and A / D conversion, the signals are wirelessly transmitted to the PC-side signal processing and display module 5 for data display and collision detection. When a collision is detected, the PC-side signal processing and display module 5 generates a collision signal and transmits it to the external PLC controller 2. The external PLC controller 2 controls the built-in relay 3 to disconnect, thereby realizing the emergency stop of the machine tool system 4.

[0085] The resistance strain gauge group 103 includes resistance strain gauges R1-R16.

[0086] The resistance strain gauges R1 to R4 form a Wheatstone bridge to measure the X-direction force.

[0087] The resistance strain gauges R5~R8 form a Wheatstone bridge to measure the Y-direction force.

[0088] The resistance strain gauges R9 to R16 form a Wheatstone bridge to measure the Z-axis force.

[0089] The third extension block of the shank cone structure 101 is also provided with several wire outlet slots 1014 for routing the first hardware circuit board 106, the second hardware circuit board 107, the resistance strain gauge group 103 and the lithium battery 109.

[0090] The protective shell 104 is also provided with a power switch hole 1042 and a charging port hole 1043 on its side.

[0091] The first hardware circuit board 106 includes a signal conditioning module and a data processing module.

[0092] Example 2:

[0093] See Figures 1 to 8 A multi-sensor integrated intelligent tool holder real-time monitoring and anti-collision system is composed of an intelligent tool holder device 1, an external PLC controller 2, an internal relay 3, and a machine tool system 4.

[0094] The intelligent tool holder device 1 includes a tool holder taper structure 101, a strain gauge force sensor structure 102, a force sensor structure fixing screw, a resistance strain gauge group 103, a protective shell 104, a protective shell fixing screw, a force sensor fixing screw, a supporting copper column 105, a first hardware circuit board 106, a hardware circuit first fixing screw, a second hardware circuit board 107, a hardware circuit second fixing screw, a vibration sensor 108, a lithium battery 109, a lithium battery fixing upper shell 110, a lithium battery fixing lower shell 111, a lithium battery fixing screw, a circuit power supply module, a signal acquisition and conditioning module, a data processing module, a wireless transmission module, a pull pin 112, a retaining ring 113, a pressure cap 114, an end mill 115, and a PC-side signal processing and display module 5.

[0095] In the intelligent tool holder device, one end of the strain gauge force sensor structure is connected to the tool holder taper structure via bolts, and the other end is connected to the end mill via a retaining ring and a pressure cap. A resistance strain gauge group is attached to the strain gauge force sensor structure. The resistance strain gauge group consists of 16 resistance strain gauges, R1 to R16. Among them, strain gauges R1 to R4 form a Wheatstone bridge to measure the X-axis force, strain gauges R5 to R8 form a Wheatstone bridge to measure the Y-axis force, and strain gauges R9 to R16 form a Wheatstone bridge to measure the Z-axis force. The wires leading out from the resistance strain gauge group are connected to the first hardware circuit board.

[0096] The lithium battery is fixed to the tool holder cone structure by a lithium battery fixing upper shell, a lithium battery fixing lower shell, and lithium battery fixing screws; the first hardware circuit board consists of two semi-circular circuit boards, the external thread of the supporting copper pillar is connected to the tool holder cone structure, and the internal thread is fixed to the first hardware circuit board by the first fixing screw of the hardware circuit; the tool holder cone structure has a wire outlet groove for the first hardware circuit board, the second hardware circuit board, the resistance strain gauge group and the lithium battery wiring.

[0097] A vibration sensor is soldered onto the second hardware circuit board, which is fixed to the strain gauge force sensor structure by a second fixing screw of the hardware circuit; wires on the second hardware circuit board are connected to the first hardware circuit board to realize power supply and data exchange.

[0098] The protective case is fixed to the shank cone structure of the tool holder with screws, and a power switch hole and a power charging hole are opened on the side of the protective case.

[0099] The external PLC controller is connected to the PC-side signal processing and display module of the intelligent tool holder device and the built-in relay of the machine tool system. The PC-side signal processing and display module continuously receives and displays the cutting signals emitted from inside the tool holder. When a collision occurs, the PC-side signal processing and display module senses the sudden change in the cutting signal and generates a collision signal. The collision signal is quickly transmitted to the external PLC controller through the data line. The external PLC controller controls the built-in relay of the machine tool system to achieve an emergency stop.

[0100] Example 3:

[0101] See Figures 1 to 8 A multi-sensor integrated intelligent toolholder real-time monitoring and anti-collision system is described. During the installation and assembly of the intelligent toolholder device, one end of the toolholder taper structure 101 is connected to the strain gauge force sensor structure 102 via a force sensor structure fixing screw, and the other end is connected to a pull stud 112. The strain gauge force sensor structure 102, a retaining ring 113, and a pressure cap 114 work together to clamp the end mill 115. The lithium battery 109 is fixed to the toolholder taper structure 101 by a lithium battery fixing upper shell 110, a lithium battery fixing lower shell 111, and lithium battery fixing screws. The first hardware circuit board 106 consists of two semi-circular circuit boards. The external thread of the supporting copper pillar 105 is connected to the toolholder taper structure 101, and the internal thread is fixed to the first hardware circuit board 106 via a hardware circuit first fixing screw. A vibration sensor 108 is soldered onto the second hardware circuit board 107, which is fixed to the second hardware circuit groove of the strain gauge force sensor structure 102 by a second hardware circuit fixing screw. The second hardware circuit board 107 has wires connected to the first hardware circuit board 106 to realize power supply and data exchange. The tool handle taper structure 101 has a wire outlet groove 1014 for the first hardware circuit board 106, the second hardware circuit board 107, the resistance strain gauge group 103 and the lithium battery 109 to run. The protective shell 104 is fixed to the tool handle taper structure 101 by screws, and a power switch hole 1042 and a charging port hole 1043 are opened on the side of the protective shell 104.

[0102] The resistive strain gauge group 103 is attached to the strain force sensor structure 102. The resistive strain gauge group 103 consists of 16 resistive strain gauges R1 to R16. Among them, strain gauges R1 to R4 form a Wheatstone bridge to measure the X-direction force, strain gauges R5 to R8 form a Wheatstone bridge to measure the Y-direction force, and strain gauges R9 to R16 form a Wheatstone bridge to measure the Z-direction force. The wires led out from the resistive strain gauge group 103 are connected to the first hardware circuit board 106.

[0103] like Figure 1 As shown, the intelligent tool holder real-time monitoring and anti-collision system integrating multiple sensors consists of an intelligent tool holder device 1, an external PLC controller 2, a built-in relay 3, and a machine tool system 4. The intelligent tool holder device 1 serves as the sensing unit and signal receiving and processing unit, the external PLC controller 2 serves as the control unit, and the built-in relay 3 and machine tool system 4 serve as the execution units.

[0104] Before milling begins, the tool holder is powered via a Type-C charging port to ensure sufficient power for operation. The power switch controls the on / off state of the lithium battery 109 within the tool holder, thereby controlling the operation and shutdown of the internal hardware circuitry of the intelligent tool holder device. The PC-side signal processing and display module 5 of the intelligent tool holder device is connected to the tool holder body via WiFi for data transmission and display. Simultaneously, the PC-side signal processing and display module 5 is connected to an external PLC controller 2 via a data cable. The built-in relay 3 is connected in series with the machine tool's internal CNC panel and the hand-cranked emergency stop relay, maintaining the same normally closed state. The PLC controller 2 is connected to the built-in relay 3 via a data cable. By controlling the external PLC controller 2, the on / off state of the built-in relay 3 is controlled, thus achieving emergency stop control of the machine tool.

[0105] When the intelligent tool holder device is powered on, the lithium battery 109 and the circuit power supply module provide a stable voltage to the data acquisition hardware circuit and the connected resistive strain gauge group 103 and vibration sensor 108. During milling or when a collision occurs, the tool contacts the workpiece and is subjected to a reaction cutting force. This cutting force is successively transmitted to the strain gauge force sensor structure 102 through the tool and the retaining ring 113. Radial forces in the X and Y directions and axial forces in the Z direction are generated on the strain gauge force sensor structure 102, causing a slight deformation of the strain gauge force sensor structure 102. The resistance of the resistive strain gauge attached to the strain gauge force sensor structure 102 changes accordingly. After applying the excitation voltage U0, the corresponding three Wheatstone bridges generate millivolt voltage signals Ux, Uy, and Uz and transmit them to the signal acquisition and conditioning module. When the tool contacts the workpiece, cutting vibration is generated and transmitted to the vibration sensor 108 on the second hardware circuit board 107 through the tool, the retaining ring 113, and the strain gauge force sensor structure 102. The millivolt analog signal generated by the vibration sensor 108 is transmitted to the signal acquisition and conditioning module of the first hardware circuit board 106 through the external wires on the second hardware circuit board 107.

[0106] like Figure 7 As shown, the signals generated by the resistance strain gauge group 103 and the vibration sensor 108 are amplified and filtered by the signal acquisition and conditioning module. Then, after data processing and A / D conversion by the data processing module, the signals enter the wireless transmission module. After wireless transmission, the signals are sent to the PC-side signal processing and display module 5 for data display and collision detection. When a collision occurs, the PC-side signal processing and display module 5 detects abnormal changes in the cutting data and sends a corresponding command to the external PLC controller 2 via the data line. The external PLC controller 2 quickly controls the built-in relay 3 in the machine tool system 4 to disconnect, causing the machine tool to stop rapidly.

[0107] This multi-sensor integrated intelligent tool holder real-time monitoring system and method can directly measure the cutting force and cutting vibration of a rotating tool, and perform real-time analysis and rapid judgment and response based on the collected cutting signals. It is unaffected by the processing environment and the shape and size of the workpiece, and the measurement is accurate. It greatly reduces the impact of the distance of the external sensor placement on the accuracy of cutting data. This device is suitable for monitoring cutting force and vibration and collision prevention during the part processing, improving the level of automation, intelligence and safety in cutting.

Claims

1. A multi-sensor integrated intelligent tool holder real-time monitoring and anti-collision system, characterized in that, include: Intelligent tool holder device (1), external PLC controller (2), built-in relay (3), machine tool system (4) and PC-side signal processing and display module (5); The intelligent tool holder device (1) includes: a shank cone structure (101), a force sensor structure (102), a resistance strain gauge group (103), a protective shell (104), several supporting copper pillars (105), a first hardware circuit board (106), a second hardware circuit board (107), a vibration sensor (108), a lithium battery (109), a fixed upper shell (110), a fixed bottom shell (111), a pull stud (112), a retaining ring (113), a pressure cap (114), and an end mill (115). The shank cone structure (101) is a cone with its top end cut off, and the lower end of the shank cone structure (101) has three outward extension blocks. A first groove (1011) is provided between the second extension block and the third extension block of the shank cone structure (101); The top of the inner side of the first groove (1011) of the shank cone structure (101) is provided with a first screw hole (10111); The second extension block of the shank tapered structure (101) is provided with a plurality of second screw holes (1012), and the second screw holes (1012) are parallel to the axial direction of the shank tapered structure (101); The third extension block of the shank cone structure (101) is provided with a plurality of first through holes (1013); The bottom of the shank cone structure (101) is provided with an inward opening (1016); The third extension block of the shank cone structure (101) is provided with a plurality of sixth screw holes (1017); The force sensor structure (102) is a cylinder, and the side of the force sensor structure (102) is provided with a plurality of second grooves (1021), and the second grooves (1021) are provided with I-shaped support columns. The force sensor structure (102) has an extension block extending outward at its lower end; the extension block at the lower end of the force sensor structure (102) has a thread on its outer side; The top end of the force sensor structure (102) is provided with a third screw hole (1022) that matches the first through hole (1013) of the shank cone structure (101). The force sensor structure (102) has a second through hole (1023) at its center; The force sensor structure (102) has a third groove (1024) at the upper end of the second through hole (1023); The third groove (1024) of the force sensor structure (102) is provided with a fourth screw hole (1025) inward; The protective shell (104) is a cylindrical shell, and the top is provided with a third through hole (1041) that matches the second screw hole (1012) of the shank cone structure (101); The first hardware circuit board (106) includes two semi-circular circuit boards; The first hardware circuit board (106) is provided with a plurality of fourth through holes (1061); The second hardware circuit board (107) is provided with a plurality of fifth through holes (1071); The fixed upper shell (110) is provided with a sixth through hole (1101); The fixed bottom shell (111) is provided with a seventh through hole (1111) that matches the sixth through hole (1101) of the fixed upper shell (110); The fixed bottom shell (111) is provided with an eighth through hole (1112); The first through hole (1013) of the shank-taper structure (101), the eighth through hole (1112) of the fixed base shell (111), and the third screw hole (1022) of the force sensor structure (102) are fixedly connected by screws; the resistive strain gauge group (103) is pasted on the I-shaped support column of the force sensor structure (102), and the wires led out from the resistive strain gauge group (103) are connected to the first hardware circuit board (106); the third through hole (1041) of the protective shell (104) and the shank-taper structure (101) are fixedly connected by screws. 1) The second screw hole (1012) is fixedly connected by screws; the supporting copper column (105) is fixedly connected to the first screw hole (10111) of the shank cone structure (101), and the fourth through hole (1061) of the first hardware circuit board (106) and the supporting copper column (105) are fixedly connected by screws; the fifth through hole (1071) of the second hardware circuit board (107) and the fourth screw hole (1025) of the force sensor structure (102) are connected by screws, and the second hardware circuit board (107) is located at the force sensor The sensor structure (102) is located in the third groove (1024); the wires leading out from the second hardware circuit board (107) are connected to the first hardware circuit board (106) to realize power supply and data exchange; the vibration sensor (108) is soldered to the second hardware circuit board (107); the lithium battery (109) is located between the fixed upper shell (110) and the fixed bottom shell (111); the sixth through hole (1101) of the fixed upper shell (110), the seventh through hole (1111) of the fixed bottom shell (111) and the shank cone structure The sixth screw hole (1017) of the body (101) is fixedly connected by screws; the fixed bottom shell (111) is located on the third extension block of the shank tapered structure (101); the pull stud (112) is located inside the shank tapered structure (101); the end mill (115) is located inside the second through hole (1023) of the force sensor structure (102); the snap ring (113) is limited between the end mill (115) and the pressure cap (114); the pressure cap (114) is fixedly connected to the thread at the lower end of the force sensor structure (102); The external PLC controller (2) is connected to both the PC-side signal processing and display module (5) and the built-in relay (3). After sensing the collision of the end mill (115), the PC-side signal processing and display module (5) generates a collision signal and transmits it to the external PLC controller (2). The external PLC controller (2) controls the built-in relay (3) to achieve an emergency stop of the machine tool system (4). The PC-side signal processing and display module (5) is connected to the intelligent tool holder device (1) via WIFI to achieve data transmission and display. When a collision occurs during milling, the end mill (115) contacts the workpiece and is subjected to a reaction cutting force. This cutting force is successively transmitted to the force sensor structure (102) through the end mill (115) and the snap ring (113). The resistance strain gauge group (103) attached to the force sensor structure (102) and the vibration sensor (108) welded to the second hardware circuit board (107) collect the corresponding signals and transmit them to the first hardware circuit board (106). After processing, the signals are wirelessly transmitted to the PC signal processing and display module (5) for data display and collision judgment. When a collision is judged, the PC signal processing and display module (5) generates a collision signal and transmits it to the external PLC controller (2). The external PLC controller (2) controls the built-in relay (3) to disconnect, thereby realizing the emergency stop of the machine tool system (4).

2. The intelligent real-time monitoring and anti-collision system for tool holders integrating multiple sensors according to claim 1, characterized in that, The resistance strain gauge group (103) includes resistance strain gauges R1-R16; The resistance strain gauges R1~R4 form a Wheatstone bridge to measure the X-direction force; The resistance strain gauges R5~R8 form a Wheatstone bridge to measure the Y-direction force; The resistance strain gauges R9 to R16 form a Wheatstone bridge to measure the Z-axis force.

3. The intelligent real-time monitoring and anti-collision system for tool holders integrating multiple sensors according to claim 1, characterized in that, The third extension block of the shank cone structure (101) is also provided with several wire outlet slots (1014) for wiring of the first hardware circuit board (106), the second hardware circuit board (107), the resistance strain gauge group (103) and the lithium battery (109).

4. The intelligent real-time monitoring and anti-collision system for tool holders integrating multiple sensors according to claim 1, characterized in that, The protective shell (104) is also provided with a power switch hole (1042) and a charging port hole (1043) on its side.

5. The intelligent real-time monitoring and anti-collision system for tool holders integrating multiple sensors according to claim 1, characterized in that, The first hardware circuit board (106) includes a signal conditioning module and a data processing module.

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