A method and system for monitoring the operation status of a rotary tongue and groove broaching machine

Abstract

The present invention relates to the technical field of industrial equipment operation status monitoring, and specifically discloses a method for monitoring the operation status of a wheel mortise and tenon broaching machine, comprising the following steps: Step 1: collecting the main operation data of the wheel mortise and tenon broaching machine; Step 2: establishing an operation data set D of the wheel mortise and tenon broaching machine; k ; Step 3: Using the collected running data set D k , establish the broach tooth pitch x 1 , broach tooth lift x 2 , cutting area x 3 , broaching speed x 4 , workpiece thickness x 5 , workpiece material hardness x 6 With the motor current x 7 , and the functional relationship between the bed vibration index value; step 4: calculating the state evaluation index value H of the wheel disc tenon and groove broaching machine; then calculating the state evaluation index value according to the following method; step 5: evaluating the operating state of the wheel disc tenon and groove broaching machine by monitoring the change of the state evaluation index value. The present invention improves the processing efficiency and yield rate of the wheel disc.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial equipment operation status monitoring, and in particular to an operation status monitoring method and a system thereof for a wheel mortise and tenon broaching machine. Background Art

[0002] Turbine discs and compressor discs (referred to as discs) are key parts of aircraft engines and gas turbines. The disc tenon and groove broaching machine is a key equipment for processing the disc tenon and groove. By monitoring the operating status data of the disc tenon and groove broaching machine and establishing evaluation indicators to characterize the operating status, it is helpful to take maintenance measures in time according to the changes in status indicators, improve the processing efficiency and yield rate of the disc, and avoid major economic losses. At present, there is a lack of effective methods for monitoring the status of the disc tenon and groove broaching machine, especially methods that can monitor the deterioration process of the operating status, which makes it difficult to avoid sudden failures of the broaching machine during the processing process. Summary of the invention

[0003] The purpose of the embodiments of the present application is to provide a method and system for monitoring the operating status of a wheel disc tenon and groove broaching machine, aiming to solve the technical problem of how to use the operating data of the wheel disc tenon and groove broaching machine to realize status monitoring, avoid sudden failure of the broaching machine during the processing, and improve the processing efficiency and yield rate of the wheel disc.

[0004] The above-mentioned purpose of the present invention is mainly achieved through the following technical solutions:

[0005] Step 1): Collect the main operation data of the wheel mortise and tenon broaching machine. During the mortise and tenon broaching process, collect the given broaching tool pitch. Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness Motor current under equal processing conditions X-direction vibration index of bed Bed Y direction vibration index value Z-direction vibration index of the bed Where i = 1, 2, 3...M, M is the data number;

[0006] Motor current Vibration index value of bed X direction (left and right) Bed Y direction (front and back) vibration index value Bed Z direction (up and down) vibration index value The method to obtain is as follows:

[0007] 1.1) During the mortise and tenon broaching process, the motor is collected at a given broach pitch. Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness The current waveform and the vibration acceleration waveform of the bed in the X, Y, and Z directions during continuous operation of n revolutions under the same conditions; each current waveform contains N j Current data I j The vibration waveforms of the bed in the X, Y, and Z directions include N j Vibration acceleration data V X,j 、V Y,j 、V Z,j ,j=1,2,…N j ,N j is a positive integer;

[0008] 1.2) Calculate the motor current Vibration index values ​​of the bed in the X, Y and Z directions The calculation method of is shown in formulas (1), (2), (3) and (4);

[0009]

[0010]

[0011] Step 2): Establish the normal state (normal operation state means that all parameters of the broaching machine are within the set range) and the wheel mortise and tenon broaching machine operation data set D k , as shown in Formula 5, where k = 1, 2, 3...K, K is a positive integer. The data collected when processing the same specification of mortise and tenon grooves are put into the same data set; if K specifications of mortise and tenon grooves are processed, K data sets are collected.

[0012]

[0013] Step 3): Using the collected running data set D k , establish the functional relationship between broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6 and motor current x7, bed vibration index value, including:

[0014] 3.1) Through regression analysis, the functional relationship between broach pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6 and motor current x7 is established

[0015] 3.2) Through regression analysis, the functional relationship between broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6, motor current x7 and bed X-direction vibration index value x8 is established

[0016] 3.3) Through regression analysis, the functional relationship between broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6, motor current x7 and bed Y direction vibration index value x9 is established.

[0017] 3.4) Through regression analysis, the functional relationship between broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6, motor current x7 and bed X-direction vibration index value x8 is established.

[0018] Step 4): Calculate the wheel mortise and tenon broaching machine status evaluation index value H. Monitor the given broaching tool pitch Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness Motor current under equal processing conditions X-direction vibration index of bed Bed Y direction vibration index value Z-direction vibration index of the bed Then calculate the status evaluation index value according to the following method.

[0019] 4.1) Through the functional relationship described in step 3.1 Calculate the current first The predicted value of Then the average value of the relative deviation of the current is calculated according to formula (6).

[0020]

[0021] 4.2) Through the functional relationship described in step 3.2 First calculate the X-direction vibration index value of the bed The predicted value of Then, the relative deviation average value of the vibration index value in the X direction is calculated according to formula (7).

[0022]

[0023] 4.3) Through the functional relationship described in step 3.3 First calculate the Y direction vibration index value of the bed The predicted value of Then, the average value of the relative deviation of the vibration index value in the Y direction is calculated according to formula (8).

[0024]

[0025] 4.4) Through the functional relationship described in step 3.4 Calculate the Z-direction vibration index of the bed The predicted value of Then, the average value of the relative deviation of the vibration index value in the Z direction is calculated according to formula (9).

[0026]

[0027] 4.5) According to formula (10), calculate the state index value H of the wheel mortise and tenon broaching machine:

[0028]

[0029] Step 5): Evaluate the operating status of the rotary tongue and groove broaching machine by monitoring the changes in the status evaluation index values. The specific method is as follows:

[0030] 5.1) Using the collected normal state data set D k , calculate the standard value H0 of the status evaluation index of the wheel mortise and tenon broaching machine according to the method shown in step (4).

[0031] 5.2) Using the data collected under the fault state (fault state means that the operation data of the broaching machine deviates from the set range), including the establishment of broaching tool pitch, broaching tool tooth lift, cutting area, broaching speed, workpiece thickness, workpiece material hardness, motor current, and bed vibration index values, calculate the state evaluation index value H according to the method shown in step 4). F , and used as the fault threshold.

[0032] 5.3) During the wheel mortise and tenon broaching process, monitor the given broach pitch Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness Single motor current under equal processing conditions X-direction vibration index of bed Bed Y direction vibration index value Z-direction vibration index of the bed And calculate the state evaluation index value H according to the method shown in step (4) m .

[0033] 5.4) By analyzing and comparing the monitored index values ​​H m The deviation degree from the standard value H0 is used to evaluate the deterioration of the rotary tongue and groove broaching machine; if H m Gradually approaching the threshold H F, then take appropriate maintenance measures to avoid sudden failure of the broaching machine during processing.

[0034] The present invention provides an operation status monitoring system for a roulette mortise and tenon broaching machine, comprising: a data acquisition unit, used for acquiring operation status data; a data processing unit, used for acquiring a data set of operation data; a state evaluation index value calculation unit, used for inputting the operation status data into the index value calculation unit to acquire the operation status index value; a state monitoring and early warning unit, used for acquiring a standard value H0 of the state evaluation index value, and based on the threshold value H F Generate the state detection result of the wheel disc tenon and groove broaching machine; the data storage module is used to store the state monitoring data and analysis results of the main drive system of the wheel disc tenon and groove broaching machine.

[0035] The technical solution of the present invention may include the following beneficial effects:

[0036] The present invention solves the technical problem of monitoring the operating status of a wheel disc tenon and groove broaching machine by adopting a data-driven status monitoring technical solution, thereby avoiding sudden failures of the broaching machine during the processing and improving the processing efficiency and yield rate of the wheel disc. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a schematic diagram of the installation position of the vibration sensor of the present invention. DETAILED DESCRIPTION

[0038] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0039] The present invention provides an operation status monitoring system for a roulette mortise and tenon broaching machine, comprising: a data acquisition unit, used for acquiring operation status data; a data processing unit, used for acquiring a data set of operation data; a state evaluation index value calculation unit, used for inputting the operation status data into the index value calculation unit to acquire the operation status index value; a state monitoring and early warning unit, used for acquiring a standard value H0 of the state evaluation index value, and based on the credible threshold H F Generate the state detection result of the wheel disc tenon and groove broaching machine; the data storage module is used to store the state monitoring data and analysis results of the main drive system of the wheel disc tenon and groove broaching machine.

[0040] The present invention provides a method for monitoring the operating status of a wheel tongue and groove broaching machine, which may include the following steps:

[0041] Step (1): Collect the main operation data of the wheel mortise and tenon broaching machine. Collect the broach tooth pitch Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness Motor current X-direction vibration index of bed Bed Y direction vibration index value Z-direction vibration index of the bed Where i = 1, 2, 3...M, M is the data number;

[0042] Motor current Vibration index value of bed X direction (left and right) Bed Y direction (front and back) vibration index value Bed Z direction (up and down) vibration index value The method to obtain is as follows:

[0043] (1.1) Calculate the broach tooth pitch according to the broach design drawing Broach tooth lift Cutting area Setting the broaching speed 2 m / min; measure workpiece thickness Workpiece material hardness The data acquisition system monitors the motor driver to monitor the current waveform of the motor during each rotation and the vibration acceleration waveform data of the bed in the X, Y, and Z directions;

[0044] (1.2) Calculate the motor current using the current waveform collected during each motor revolution and the vibration acceleration waveform data of the bed in the X, Y, and Z directions Vibration index values ​​of the bed in the X, Y and Z directions The calculation method of is shown in formulas (1), (2), (3) and (4);

[0045]

[0046] Step (2): Establish a data set D of the wheel mortise and tenon broaching machine under normal conditions, as shown in Formula 5. During the test, only mortises with the same specifications are processed, so the number of data sets collected is 1.

[0047]

[0048] Step (3): Using the collected operating data set D, establish the functional relationship between the broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6 and motor current x7, bed vibration index value. The specific process is as follows:

[0049] (3.1) Based on the MATLAB software platform, a deep neural network basic model is built. The collected broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, and workpiece material hardness x6 are used as input data, and the motor current x7 is used as output data. A regression prediction model for the motor current x7 is established through model training. In this embodiment, the basic model structure of the deep neural network includes three parts: input layer, hidden layer and output layer, where the number of neurons is 128, the batch size is 112, the learning rate is 0.001, and the number of iterations is 180.

[0050] (3.2) Based on the MATLAB software platform, a deep neural network basic model is built. The collected broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6, and motor current x7 are used as input data, and the X-direction vibration index value of the bed x8 is used as output data. A regression prediction model for the motor current x7 is established through model training.

[0051] (3.3) Based on the MATLAB software platform, a deep neural network basic model is built. The collected broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6, and motor current x7 are used as input data, and the bed Y direction vibration index value x9 is used as output data. The regression prediction model of motor current x7 is established through model training.

[0052] (3.4) Based on the MATLAB software platform, a deep neural network basic model is built, and the collected broach pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6, motor current x7 are used as input data, and the Z-direction vibration index value of the bed x 10 As output data, a regression prediction model of motor current x7 is established through model training.

[0053] It can be seen from the above embodiments that the present application solves the technical problem of how to extract motor performance degradation indicators and mechanical performance degradation indicators using the operating status data of the wheel tongue and groove broaching machine under conditions of strong environmental noise interference by adopting data regression prediction technology, thereby achieving the technical effect of synchronous extraction of motor and mechanical performance degradation indicators of the wheel tongue and groove broaching machine.

[0054] Step (4): Calculate the state evaluation index value H of the roulette mortise and tenon broaching machine. The calculation process is as follows: The state evaluation index value is calculated by the following method.

[0055] (4.1) Input the monitored data set into the model described in 3.1 Calculate the current The predicted value of Then the average value of the current relative deviation is calculated according to formula (6).

[0056]

[0057] (4.2) Input the monitored data set into the model described in 3.2 Calculate the X-direction vibration index of the bed The predicted value of Then, the relative deviation average value of the vibration index value in the X direction is calculated according to formula (7).

[0058]

[0059] (4.3) Input the monitored data set into the model described in 3.3 First calculate the Y-direction vibration index value of the bed The predicted value of Then, the average value of the relative deviation of the vibration index value in the Y direction is calculated according to formula (8).

[0060]

[0061] (4.4) Input the monitored data set into the model described in 3.4 First calculate the Z-direction vibration index value of the bed The predicted value of Then, the average value of the relative deviation of the vibration index value in the Z direction is calculated according to formula (9).

[0062]

[0063] (4.5) According to formula (10), calculate the state index value H of the wheel mortise and tenon broaching machine:

[0064]

[0065] It can be seen from the above embodiments that the wheel disc tenon and groove broaching machine state index value calculated by the method proposed in this application solves the technical problem of comprehensive characterization of the wheel disc tenon and groove broaching machine state, and achieves the technical effect of synchronous monitoring of the wheel disc tenon and groove broaching machine motor and mechanical state changes.

[0066] Step (5): Evaluate the operating status of the rotary tongue and groove broaching machine by monitoring the change of the status evaluation index value. The specific method is as follows:

[0067] (5.1) Using the collected data set D under normal conditions k , calculate the standard value H0 of the status evaluation index of the wheel mortise and tenon broaching machine according to the method shown in step (4).

[0068] (5.2) Through the fault injection technology, the operating status data under the fault state is collected, including the establishment of broaching tool pitch, broaching tool tooth lift, cutting area, broaching speed, workpiece thickness, workpiece material hardness, motor current, and bed vibration index values; the state evaluation index value H is calculated according to the method shown in step (4) F , as the fault threshold.

[0069] (5.3) During the wheel mortise and tenon broaching process, monitor the given broaching tool pitch Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness Single motor current under equal processing conditions X-direction vibration index of bed Bed Y direction vibration index value Z-direction vibration index of the bed And calculate the state evaluation index value H according to the method shown in step (4) m .

[0070] (5.4) Analysis and comparison of monitoring index value H m The degree of deviation from the standard value H0 determines the degree of deterioration of the wheel mortise and tenon broaching machine; if H m Gradually approaching the threshold H F , take necessary maintenance measures to avoid failure.

[0071] According to the method and steps, the state data of the main drive system of the wheel mortise and tenon broaching machine in normal and abnormal states are measured respectively, including broaching tool pitch, broaching tool tooth lift, cutting area, broaching speed, workpiece thickness, workpiece material hardness, motor current, and bed vibration index value; the installation position of the vibration sensor is as follows: Figure 1 Then, according to step 1 to step 7, the health indicators under different states are calculated, as shown in the table. The implementation case results show that when the running state of the wheel mortise and tenon broaching machine changes, the degree of comprehensive performance degradation can be determined according to the method of the present invention, and fault warning can be achieved accordingly.

[0072] By collecting data of different degradation states of the main drive system of the wheel tenon and groove broaching machine, a database of the wheel tenon and groove broaching machine working in different degradation states is obtained, and the state detection index is calculated according to the technical solution of the present invention, and the results are shown in Table 1. With the degradation of performance, the state index value H of the wheel tenon and groove broaching machine gradually increases. After analysis and testing, when the state index value of the wheel tenon and groove broaching machine reaches 14.0%, it cannot meet the use requirements. In order to achieve early fault warning, the minimum value of 11.2% under the fault state can be used as the fault threshold.

[0073] Table 1 Comparison of HI under different conditions

[0074]

[0075]

Claims

1. A method for monitoring the operating status of a rotary tongue and groove broaching machine, characterized in that: The steps include: Step 1: Collect the operation data of the roulette mortise and tenon broaching machine; Step 1: During the mortise and tenon broaching process, collect the given broach tooth pitch Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness Motor current under machining conditions X-direction vibration index of bed Bed Y direction vibration index value Z-direction vibration index of the bed Where i = 1, 2, 3...M, M is the data number; Motor current X-direction vibration index of bed Bed Y direction vibration index value Z-direction vibration index of the bed The method to obtain is as follows: 1.1) During the mortise and tenon broaching process, the motor is collected at a given broach pitch. Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness The current waveform and the vibration acceleration waveform of the bed in the X, Y, and Z directions during continuous operation under the condition of n revolutions; each current waveform contains N j Current data I j The vibration waveforms of the bed in the X, Y, and Z directions include N j Vibration acceleration data V X,j 、V Y,j 、V Z,j ,j=1,2,…N j ,N j is a positive integer; 1.2) Calculate the motor current Vibration index values ​​of bed in X, Y and Z directions The calculation method of is shown in formulas (1), (2), (3) and (4); Step 2: Establish the running data set D of the roulette mortise and tenon broaching machine under normal operation k ; Normal operation state means that all parameters of the broaching machine are within the set range; Step 3: Use the collected running dataset D k , establish the functional relationship between broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6 and motor current x7, bed vibration index value; Step 4: Monitor the given broach pitch Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness Motor current under machining conditions X-direction vibration index of bed Bed Y direction vibration index value Z-direction vibration index of the bed Calculate the state evaluation index value H of the roulette mortise and tenon broaching machine; Step 5: Evaluate the operating state of the wheel mortise and tenon broaching machine by monitoring the change of the state evaluation index value H; Step 5 is as follows: 5.1) Using the collected data set D under normal operation k , calculate the standard value H0 of the status evaluation index value of the wheel mortise and tenon broaching machine according to step 4; 5.2) Collect the data set under the fault state, including the establishment of broach pitch, broach tooth lift, cutting area, broaching speed, workpiece thickness, workpiece material hardness, motor current, and bed vibration index values, and calculate the state evaluation index value H according to the method shown in step 4 F , and used as the fault threshold; the fault state means that the operating data of the broaching machine deviates from the set range; 5.3) During the wheel mortise and tenon broaching process, monitor the given broach pitch Broach tooth lift Cutting area Broaching speed Workpiece thickness Workpiece material hardness Single motor current under machining conditions X-direction vibration index of bed Bed Y direction vibration index value Z-direction vibration index of the bed And calculate the state evaluation index value H according to step 4 m ; 5.4) By analyzing and comparing the monitored index values ​​H m The deviation degree from the standard value H0 is used to evaluate the deterioration of the rotary tongue and groove broaching machine; if H m Gradually approaching the threshold H F , then take appropriate maintenance measures to avoid sudden failure of the broaching machine during processing.

2. A method for monitoring the operating status of a rotary tongue and groove broaching machine according to claim 1, characterized in that: Step 2D k The expression is as follows: Where k = 1, 2, 3...K, K is a positive integer; the data collected when processing the same specification of mortise and tenon grooves are put into the same data set; if K specifications of mortise and tenon grooves are processed, K data sets are collected.

3. The method for monitoring the operation status of a rotary tongue and groove broaching machine according to claim 1, characterized in that step 3 is specifically as follows: 3.1) Through regression analysis, the functional relationship between broach pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6 and motor current x7 is established 3.2) Through regression analysis, the functional relationship between broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6, motor current x7 and bed X-direction vibration index value x8 is established 3.3) Through regression analysis, the functional relationship between broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6, motor current x7 and bed Y direction vibration index value x9 is established. 3.4) Through regression analysis, the relationship between broach tooth pitch x1, broach tooth lift x2, cutting area x3, broaching speed x4, workpiece thickness x5, workpiece material hardness x6, motor current x7 and bed Z direction vibration index x is established. 10 Functional relationship between 4. The method for monitoring the operating status of a rotary tongue and groove broaching machine according to claim 3, wherein step 4 is specifically as follows: 4.1) Through the functional relationship described in step 3.1 Calculate the current first The predicted value of Then the average value of the relative deviation of the current is calculated according to formula (6); 4.2) Through the functional relationship described in step 3.2 First calculate the X-direction vibration index value of the bed The predicted value of Then, the relative deviation average value of the vibration index value in the X direction is calculated according to formula (7); 4.3) Through the functional relationship described in step 3.3 First calculate the Y direction vibration index value of the bed The predicted value of Then, the average value of the relative deviation of the vibration index value in the Y direction is calculated according to formula (8); 4.4) Through the functional relationship described in step 3.4 Calculate the Z-direction vibration index of the bed The predicted value of Then, the average value of the relative deviation of the vibration index value in the Z direction is calculated according to formula (9); 4.5) According to formula (10), calculate the state index value H of the wheel mortise and tenon broaching machine:

5. A wheel disc tenon and groove broaching machine operation status monitoring system based on the wheel disc tenon and groove broaching machine operation status monitoring method according to claim 1, characterized in that: include: A data collection unit, used for collecting operation status data; A data processing unit, used for acquiring a transfer operation data set; a state evaluation index value calculation unit, inputting the operation state data into the index value calculation unit to obtain the operation state index value; The state monitoring and early warning unit is used to obtain the standard value H0 of the state evaluation index value and based on the threshold value H F Generate the status test results of the wheel mortise and tenon broaching machine; The data storage module is used to store the status monitoring data and analysis results of the main drive system of the wheel tongue and groove broaching machine.

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