Heavy-duty tool-breakage monitoring method and device

Abstract

This invention discloses a method and device for monitoring the breakage of heavy-duty lathe tools, including a spring-loaded assembly disposed within the inner cavity of the tool body and a magnetic switch circuit. One end of the spring-loaded assembly has a spring piece, and the other end has a base block fixed to the bottom of the tool body. The spring piece is configured to be pressed against the upper cutting tool by a pre-pressure, and to spring back relative to the base block when the cutting tool falls off. The magnetic switch circuit is configured to activate the circuit when the spring piece springs back, causing the magnetic switch to engage. After receiving the electrical signal, the PLC transmits the signal to a preset macro program on the machine tool. According to preset rules, the macro program or the drop handling program performs reverse control on the machine tool. This method allows for remote monitoring without interfering with the vibration of the cutting tool itself. It features a simple structure, strong operability, and easy promotion, achieving accurate monitoring and timely reverse control of tool breakage, thereby ensuring the safety and stability of the lathe machining process.

Description

Technical Field

[0001] This invention belongs to the field of tool breakage monitoring, and relates to a method and device for monitoring the breakage of heavy-duty lathe tools. Background Technology

[0002] Tool breakage is a common but serious problem in heavy-duty lathe machining. When a tool breaks and falls off, it can cause the tool body to collide with the workpiece, resulting in severe equipment damage and personal safety risks. This is especially true when machining large cylindrical cavities, as the machining process is performed inside the workpiece, making it impossible to directly observe the machining process. Therefore, real-time monitoring and timely response to tool breakage are crucial for ensuring the safety and stability of the machining process.

[0003] Currently, traditional methods for detecting tool breakage have some limitations. For example, visual inspection requires complex image processing algorithms and is highly dependent on ambient lighting conditions.

[0004] Other sensors, such as strain gauges or vibration sensors, need to be glued or mounted on the tool surface or machine tool structure, which increases complexity and cost, and may be affected by vibration and interference in the working environment. Summary of the Invention

[0005] The purpose of this application is to provide a method and device for monitoring the breakage of heavy-duty lathe tools, in order to improve the shortcomings of current detection devices that cannot respond quickly and accurately and interfere with the vibration of the workpiece and the tool. It can monitor remotely and the monitoring process does not interfere with the vibration of the tool itself. It has a simple structure, strong operability, and is easy to promote, so as to realize accurate monitoring and timely counter-control of tool breakage, thereby ensuring the safety and stability of the lathe machining process.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0007] A heavy-duty lathe tool breakage monitoring device, characterized in that it includes:

[0008] The spring-loaded assembly and magnetic switch circuit are installed in the inner cavity of the cutter body rod;

[0009] One end of the spring-loaded assembly is equipped with a spring plate, and the other end is equipped with a base block fixed to the bottom of the blade rod. The spring plate is designed to be pressed by the blade above by pre-pressure, and to spring back relative to the base block when the blade falls off. The magnetic switch circuit is designed to be turned on and send an electrical signal when the spring plate springs up by triggering the magnetic switch through the spring plate contact.

[0010] In the above technical solution, the circuit is connected to the input port of the PLC via wires; the PLC communicates with the machine tool and transmits the control commands generated by the PLC to the machine tool.

[0011] In the above technical solution, one end of the spring-loaded assembly is a flat spring sheet, and the other end is a base block. The spring sheet is set higher than the bottom of the base block and is set horizontally with the spring sheet bouncing towards the upper surface of the base block.

[0012] In the above technical solution, a magnetic switch is set at the outer end of the spring, and another magnetic switch is set at a certain distance above the magnetic switch; the blade pre-presses the spring downward by the bolt, and the pre-pressure is set such that when the blade falls off and there is no downward pre-pressure, the bolt moves upward, the outer end of the spring releases the pressure and springs back upward, so that the two magnetic switches are combined and attracted to each other to generate a current circuit.

[0013] In the above technical solution, a small battery and a resistor are set on the base block, and the battery and the resistor are connected by wires to form a magnetic switch circuit.

[0014] In the above technical solution, the spring compression assembly is wrapped with insulating tape.

[0015] In the above technical solution, the inner cavity of the cutter body rod is set to one vertical side of the cutter body rod and is sealed from the side.

[0016] In the above technical solution, the inner cavity of the cutter body includes a horizontal groove that is basically horizontally set at the bottom of the guide rod and a vertical groove that is basically vertical; the horizontal groove and the vertical groove are interconnected to form an inner cavity with a cross-section that is basically L-shaped; it also includes a constraint hole opened on the cutter pad, the constraint hole passing through the L-shaped inner cavity and being set adjacent to the vertical groove; and a bolt that can move up and down is set vertically or basically vertically in the constraint hole.

[0017] In the above technical solution, the top constraint hole of the mounting bolt should be set close to the tip of the blade so that when the blade breaks and falls, it can quickly pop out and trigger the spring to rebound and activate the magnetic switch.

[0018] A method for monitoring the breakage of heavy-duty lathe tools based on the present invention includes the following steps:

[0019] Step 1: When the blade breaks and falls, the blade preload decreases until it disappears, the spring rebounds and causes the magnetic switch to be attracted, and the magnetic switch circuit generates current.

[0020] Step 2: After receiving the electrical signal, the PLC transmits the signal to the machine tool's preset macro program. According to the preset rules, the macro program or the fall handling program performs reverse control on the machine tool.

[0021] In the above technical solution, the rule is that when the switch is in the closed state, the current signal is 0, indicating that the tool is working normally. When the switch is in the open state, the current signal is 1, indicating that the tool has been damaged and fallen off. At this time, the machine tool NC system performs reverse control on the machine tool through preset macro instructions.

[0022] In this embodiment, the machine tool's macro program should be pre-set with rules and actions for reverse control to enable operations such as stopping the tool feed, retracting the tool, and issuing alarms.

[0023] In this embodiment, the preset macro instruction refers to stopping the machine tool feed and retracting the tool when the NC system detects a current signal of 1, and simultaneously triggering an alarm on the machine tool. The response time of this instruction is adjusted according to different strokes or tool sizes.

[0024] Therefore, this invention discloses a method and device for monitoring the breakage of heavy-duty lathe tools, belonging to the field of tool breakage condition monitoring. An intelligent device is installed inside the tool holder, and a magnetic switch enables rapid response and accurate monitoring when the tool breaks. When the tool breaks, the elastic force is released, causing the two switch contacts to make contact, thereby generating a current signal to monitor the tool breakage condition in real time.

[0025] The beneficial effects of this invention are:

[0026] This invention installs an intelligent detection device in the tool pad and the inner cavity of the tool body. When the tool breaks and falls, the device can send a signal to the NC system. The NC system performs reverse control on the machine tool according to the set rules of the current signal (such as 0, 1 rules), which effectively and timely avoids the tool body from colliding with the workpiece due to the tool breaking and falling, thereby improving production efficiency and reducing the need for manual intervention.

[0027] Compared to traditional tool breakage monitoring methods, this invention eliminates the need for complex image processing algorithms or the installation and bonding of sensors, reducing costs and complexity. Furthermore, the detection device is powered by a small button battery, eliminating the need for an external power supply and lowering energy consumption and maintenance costs.

[0028] According to preset rules, the macro program performs reverse control on the lathe to prevent the cutting tool from falling and colliding with the workpiece. This device can monitor and respond to tool breakage in a timely manner and has broad application prospects.

[0029] When the cutting edge breaks, the bolt pops out, and the spring, carrying power, attracts the power source above, generating current. This signal is transmitted to the machine tool's preset macro program via the PLC. According to preset rules, the macro program performs reverse control of the lathe. This method, through connection with both the PLC and the machine tool control system, enables timely reverse control of the machine tool, preventing the cutting tool from falling and colliding with the workpiece. It can monitor and respond to tool breakage in a timely manner and has broad application prospects.

[0030] The research background of this invention is to overcome the limitations of traditional tool breakage monitoring methods and to provide a method and device for monitoring heavy-duty lathe tool breakage, so as to achieve accurate monitoring and timely counter-control of tool breakage, thereby ensuring the safety and stability of lathe machining process. Attached Figure Description

[0031] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a perspective view of the intelligent heavy-duty lathe tool breakage monitoring device and the tool installation according to an embodiment of the present invention.

[0033] Figure 2 This is an overall appearance view of the intelligent heavy-duty lathe tool breakage monitoring device according to an example of the present invention.

[0034] Figure 3 This is a flowchart of the intelligent heavy-duty lathe tool breakage monitoring method according to an embodiment of the present invention.

[0035] Figure 4 This is a schematic diagram of the cutting tool structure in the normal state of the intelligent heavy-duty lathe tool damage monitoring device according to an embodiment of the present invention.

[0036] Figure 5 This is a schematic diagram of the lathe tool structure when the tool of the intelligent heavy-duty lathe tool damage monitoring device of this invention is damaged. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0038] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0039] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0040] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this application is in use. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0041] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0042] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0043] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0044] The features and performance of this application will be further described in detail below with reference to the embodiments.

[0045] Example 1

[0046] like Figure 1 and Figure 2As shown, the heavy-duty lathe tool breakage monitoring device according to the present invention is a spring-loaded intelligent detection device for tool fall-off, including a spring-loaded assembly 4 with a spring piece 42 at one end, and a magnetic attraction switch detection circuit that is turned on according to the change of the position of the spring piece. The spring piece 42 is pressed and set by the tool 1 by pre-pressure.

[0047] One end of the spring-loaded assembly 4 is a flat spring plate 42, and the other end is a base block 41. The spring plate 42 is set higher than the bottom of the base block 41, and the spring plate 42 is set horizontally towards the upper surface of the base block 41. Preferably, the upper surfaces of the two are flush.

[0048] In this embodiment, a magnetic switch 5 is provided at the outer end of the spring piece 42 (preferably attached), and another magnetic switch 5 is provided above the magnetic switch 5 at a certain distance (approximately equal to or slightly less than the vertical movement distance of the bolt 3). After ensuring that there is no downward preload, the bolt 3 moves upward, and the outer end of the spring piece 42 releases the pressure and rebounds upward. The two magnetic switches 5 combine and attract each other, generating a current circuit.

[0049] Correspondingly, a small battery 7 and a resistor 8 are set on the base block 41, and the battery 7 and resistor 8 are connected by a wire 11 to form a circuit, ensuring that the circuit can obtain the required power supply. The wire 11 communicates with the outside through the wire hole 9 set on the guide rod, and the wire hole 9 communicates with the inner cavity 61.

[0050] The preferred battery 7 is a button cell battery, so as to reduce the space of the detection device and make the opening of the inner cavity 61 small enough so as not to affect the force on the tool bar 6.

[0051] In this embodiment, the spring-loaded assembly 4 is configured as a combination of an iron block end and an iron sheet end, which needs to be wrapped with insulating tape.

[0052] In this embodiment, an inner cavity 61 for installing an intelligent detection device is formed inside the tool holder 6. The inner cavity 61 includes a horizontal groove 611 that is basically horizontally set at the bottom of the guide rod and a vertical groove 622 that is basically vertical. The horizontal groove 611 and the vertical groove 622 are interconnected to form an inner cavity with a basically L-shaped cross section. It also includes a constraint hole 21 formed on the tool pad 2. The constraint hole 21 passes through the L-shaped inner cavity 61 and is set adjacent to the vertical groove 622. A bolt 3 that can move up and down is vertically or basically vertically set in the constraint hole 21.

[0053] The design of the inner cavity 61 should consider sufficient space to install the intelligent monitoring device, ensuring that the size and shape of the inner cavity are suitable for the installation of the device, while ensuring the stability and protection of the device, and without affecting the blade body.

[0054] In this embodiment, the spring-loaded assembly 4 is placed into the inner cavity 61, and its position is adjusted so that the spring piece 42 is aligned with the lower end of the vertically or substantially vertically movable bolt 3. The outer end of the spring piece 42 is tightened and fixed to the bolt 3 using the bolt 3 (a fixing hole can be pre-drilled at the outer end of the spring piece 42), so that the head of the bolt 3 passes through the constraint hole 21 and presses against the blade 1, and the spring piece 42 is in a downward-pressed state and warps downward relative to the base block 41. That is, the outer end of the spring piece 42 presses against the bottom of the blade bar through the base block 41.

[0055] In this embodiment, the base block 41 is fixed to the guide rod. The connection method of the screw 10 should ensure that the end of the base block 41 is firmly fixed to the tail end of the guide rod to avoid the base block 41 becoming loose or falling off during the cutting process.

[0056] The sealing cap 12 is installed on the side of the tool holder 6 to seal the inner cavity 61, thereby sealing the aforementioned detection device within the inner cavity 61. Bolt fixing is preferred.

[0057] In this embodiment, a magnetic switch 5 is attached or fixedly installed on the spring sheet, and another magnetic switch 5 is suspended (attached) in the inner cavity and located above the first magnetic switch 5, so as to ensure that when the blade 1 breaks and falls, the pre-pressure is reduced or disappears, causing the spring sheet 42 to spring back upward.

[0058] In this embodiment, the top constraint hole 21 of the mounting bolt 3 should be positioned close to the tip of the blade 1 so that it can quickly pop out and trigger the contact switch (e.g., when the blade 1 breaks and falls) Figure 1 As shown, bolt 3 is located in the corner area outside the blade fixing hole at the blade receiving opening of blade 1.

[0059] In this embodiment, the selection of battery 7 should take into account power supply durability and replaceability, so as to monitor the blade status for a long time and replace the battery in a timely manner.

[0060] In this embodiment, the location of the wire port 9 should facilitate wire connection and ensure the reliability and stability of signal transmission. The wire is led out through the wire port 9 at the tail of the tool and connected to the input port of the PLC.

[0061] like Figure 3 As shown, a PLC is also set up to receive and process the current signal generated by the piezoelectric effect; the PLC communicates with the machine tool to transmit the control commands generated by the PLC to the machine tool.

[0062] The circuitry in the heavy-duty lathe tool is connected to a PLC. The PLC should be able to receive and process signals from intelligent devices and perform corresponding control according to preset rules.

[0063] In this embodiment, the contact occurs when the blade 1 breaks and falls off. The head of the bolt 3, no longer under pressure from the blade 1, releases and moves upward, causing the spring 42 to spring back, the contacts to make contact, the circuit to be connected, and a current signal to be generated. This contact method enables rapid response and accurate monitoring when the blade 1 breaks, and ensures the triggering of the piezoelectric effect.

[0064] Example 2:

[0065] The formation process of this device is as follows:

[0066] Step 1: Create an inner cavity inside the blade pad 2 and the blade holder 6 for installing the intelligent detection device;

[0067] Step 2: Place the spring compression assembly 4 in the inner cavity;

[0068] Step 3: The spring-loaded assembly 4 is set up as follows: the spring piece and bolt 3 are tightened and fixed so that the top of the bolt presses against the blade, and the spring piece 42 at the bottom of the bolt generates elastic force. The base block 41 is tightened and fixed to the tail of the handle with screws.

[0069] Step 4: Insulating tape is wrapped around the spring-loaded assembly 4, and a magnetic switch 5 is attached thereon. Another magnetic switch 5 is attached to the blade body above the inner cavity 61.

[0070] Step 5: The device is equipped with a small battery 7 for power supply, and a wire port 9 is opened at the tail of the cutter. This wire is connected to the PLC to transmit signals.

[0071] Step 6: After all the devices are installed, seal the inner cavity of the blade body with the sealing cap 12.

[0072] Example 3:

[0073] A method for monitoring the breakage of heavy-duty lathe tools based on the present invention includes the following steps:

[0074] Step 1: When the blade 1 breaks and falls, the bolt 3 will pop up. At this time, the elastic force causes the spring 42 to attract the magnetic switch 5 above it with its own magnetic switch 5, generating an electric current.

[0075] When the blade breaks and falls, the spring 42 rebounds, the contacts make contact, the circuit is connected, and a current signal is generated. This contact method enables rapid response and accurate monitoring when the blade breaks, and ensures the triggering of the piezoelectric effect.

[0076] Step 2: After receiving the electrical signal, the PLC transmits the signal to the machine tool's preset macro program or fall handling program. According to the preset rules, the macro program or fall handling program performs reverse control on the machine tool.

[0077] In this embodiment, the PLC is programmed with macro programs to receive and process signals transmitted from the intelligent device. Appropriate control logic is written according to preset rules to achieve reverse control of the machine tool's cutting tool falling off.

[0078] In this embodiment, the rule is that when the switch is in the closed state, the current signal is 0, indicating that the tool is working normally. When the switch is in the open state, the current signal is 1, indicating that the blade has broken and fallen off. At this time, the machine tool NC system uses preset macro instructions to reverse control the machine tool.

[0079] In this embodiment, the machine tool's macro program should be pre-set with rules and actions for reverse control to enable operations such as stopping the tool feed, retracting the tool, and issuing alarms.

[0080] In this embodiment, the preset macro instruction refers to stopping the machine tool feed and retracting the tool when the NC system detects a current signal of 1, and simultaneously triggering an alarm on the machine tool. The response time of this instruction is about 18 milliseconds, and the response time can also be adjusted according to different strokes or tool sizes.

[0081] like Figure 4 As shown, when the blade 1 is not damaged, the blade 1 is still above the blade pad 2, the magnetic switch 5 of the spring 42 itself and the magnetic switch 5 above it are not closed, and the spring 42 is in a pressed state.

[0082] like Figure 5 As shown, when the blade 1 is damaged, the blade tip breaks. At this time, the spring 42 releases its elastic force to drive the bolt 3 to push out the broken blade tip 1. The two magnetic switches 5 will attract each other to form a closed circuit and generate current.

[0083] The embodiments described above are some, but not all, of the embodiments of this application. The detailed description of the embodiments of this application is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

Claims

1. A heavy duty tool-break monitoring device, characterized in that include: A spring-loaded assembly and a magnetic switch circuit are installed inside the blade shaft. One end of the spring-loaded assembly is equipped with a spring sheet, and the other end is equipped with a base block fixed to the bottom of the blade rod. The spring sheet is designed to be pressed by the blade above under preload, and to spring back relative to the base block when the blade falls off. The magnetic switch circuit is designed to activate the circuit by the spring sheet rebounding and driving the magnetic switch to engage when the spring sheet springs back up. One end of the spring-loaded assembly is a flat spring sheet, and the other end is a base block. The spring sheet is set higher than the bottom of the base block and is set horizontally with the spring sheet springing up towards the upper surface of the base block. A magnetic switch is provided at the outer end of the spring, and another magnetic switch is provided at a certain distance above the magnetic switch; the blade is used to pre-press the spring downward by the bolt, and the pre-pressure is set such that when the blade falls off, the bolt moves upward, and the outer end of the spring rebounds, causing the two magnetic switches to attract each other to generate a current circuit.

2. The heavy duty cutter breakage monitoring device of claim 1, wherein The circuit is connected to the input port of the PLC via wires; the PLC is connected to the machine tool for communication, transmitting the control commands generated by the PLC to the machine tool.

3. The heavy duty cutter breakage monitoring device of claim 1, wherein A small battery and resistor are placed on the base block, and the battery and resistor are connected by wires to form a magnetic switch circuit.

4. The heavy duty cutter breakage monitoring device of claim 1, wherein The spring-loaded assembly is wrapped with insulating tape.

5. The heavy-duty lathe tool breakage monitoring device according to claim 1, characterized in that... The inner cavity of the cutter body is offset to one vertical side of the cutter body and is sealed from the side.

6. The heavy duty cutter breakage monitoring device of claim 1, wherein The inner cavity of the cutter body includes a horizontal groove that is basically horizontally set at the bottom of the guide rod and a vertical groove that is basically vertical. The horizontal groove and the vertical groove are connected to each other to form an L-shape. It also includes a constraint hole opened on the cutter pad, which passes through the inner cavity of the L-shape and is set adjacent to the vertical groove. A bolt that can move up and down is set vertically or basically vertically in the constraint hole.

7. The heavy duty cutter breakage monitoring device of claim 1, wherein The top constraint hole of the mounting bolt is set close to the tip of the blade so that if the blade breaks and falls, it can quickly pop out and trigger the spring to rebound.

8. A method for monitoring the breakage of heavy-duty lathe tools, using the heavy-duty lathe tool breakage monitoring device according to any one of claims 1-7, comprising the following steps: Step 1: When the blade breaks and falls, the blade preload decreases until it disappears, the spring rebounds and causes the magnetic switch to be attracted, and the magnetic switch circuit generates current. Step 2: After receiving the electrical signal, the PLC transmits the signal to the machine tool's preset macro program. According to the preset rules, the macro program or the fall handling program performs reverse control on the machine tool. The rule is that when the switch is in the closed state, the current signal is 0, indicating that the tool is working normally. When the switch is in the open state, the current signal is 1, indicating that the tool has broken and fallen off. At this time, the machine tool NC system uses preset macro instructions to reverse control the machine tool.

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