An intelligent monitoring system for screw processing

Abstract

The present invention discloses an intelligent monitoring system for screw processing, including an image information acquisition module, an environment information acquisition module, a feed information acquisition module, a production information acquisition module, a platform information acquisition module, a data processing module and an information sending module; the image information acquisition module is used to acquire image information of a feed vibration platform of a thread rolling machine during screw processing; the environment information acquisition module is used to acquire environmental information of the feed vibration platform of a thread rolling machine during screw processing; the feed information acquisition module is used to acquire feed mechanism information in the feed vibration platform of a thread rolling machine during screw processing; the platform information acquisition module is used to acquire platform-related information of the feed vibration platform of a thread rolling machine during screw processing. The present invention can conduct more comprehensive and intelligent monitoring of screw processing, ensuring that the processed screws have better quality and higher production efficiency.

Description

Technical Field

[0001] The invention relates to the field of monitoring systems, and in particular to an intelligent monitoring system for screw processing. Background Art

[0002] The processing of screws is a complex and delicate process, which mainly includes multiple steps, each of which has its specific purpose and technical requirements. The feeding vibration platform of the thread rolling machine in the screw production process is an important part of the thread rolling machine. It is responsible for feeding the screws into the thread rolling machine for processing at a certain speed and posture;

[0003] During the actual use of the thread rolling machine feeding vibration platform, the monitoring system is used to monitor the screw processing process of the thread rolling machine feeding vibration platform to ensure the stable operation of the thread rolling machine feeding vibration platform.

[0004] The existing monitoring system obtains a single type of data during the monitoring process and has a low overall intelligence level, resulting in poor monitoring results and a certain impact on the use of the monitoring system. Therefore, an intelligent monitoring system for screw processing is proposed. Summary of the invention

[0005] The technical problem to be solved by the present invention is: how to solve the problem that the existing monitoring system has a single type of data obtained during the monitoring process and a low overall intelligence level, resulting in poor monitoring effect and bringing certain impacts on the use of the monitoring system. An intelligent monitoring system for screw processing is provided.

[0006] The present invention solves the above technical problems through the following technical solutions, which include an image information acquisition module, an environmental information acquisition module, a feed information acquisition module, a production information acquisition module, a platform information acquisition module, a data processing module and an information sending module;

[0007] The image information acquisition module is used to acquire image information of the feeding vibration platform of the thread rolling machine during screw processing;

[0008] The environmental information collection module is used to collect the environmental information of the feeding vibration platform of the thread rolling machine during the screw processing;

[0009] The feeding information collection module is used to collect the feeding mechanism information in the feeding vibration platform of the thread rolling machine during the screw processing;

[0010] The platform information acquisition module is used to collect platform-related information of the feeding vibration platform of the thread rolling machine during screw processing;

[0011] The production information collection module is used to collect production information of the feeding vibration platform of the thread rolling machine during the screw processing;

[0012] The data processing module is used to process image information, environment information, feed mechanism information, platform related information and production information, and obtain platform level supervision information, environment abnormality warning information, feed abnormality warning information, platform shaking warning information and production warning information;

[0013] The information sending module is used to send the platform levelness supervision information, environmental abnormality warning information, feed abnormality warning information, platform shaking warning information and production warning information to a preset receiving terminal after the above information is generated.

[0014] Furthermore, the specific processing process of the platform levelness supervision information is as follows: extracting the collected image information, which is the image information of the feeding vibration platform of the thread rolling machine collected from four directions: the front, the rear, the left and the right;

[0015] After the feeding vibration platform of the thread rolling machine is installed, two preset marks are set on each surface thereof, which are on the same horizontal plane and have a spacing greater than a preset distance;

[0016] Extracting the front image of the feeding vibration platform of the thread rolling machine, and processing it to obtain the first evaluation parameter;

[0017] The image directly behind the feeding vibration platform of the thread rolling machine is extracted and processed to obtain the second evaluation parameter;

[0018] The left image of the feeding vibration platform of the thread rolling machine is extracted and processed to obtain the third evaluation parameter;

[0019] The right side image of the feeding vibration platform of the thread rolling machine is extracted and processed to obtain the fourth evaluation parameter;

[0020] Analyze the first evaluation parameter, the second evaluation parameter, the third evaluation parameter, and the fourth evaluation parameter to obtain a comprehensive evaluation parameter;

[0021] When the comprehensive assessment parameters are abnormal, platform level supervision information is generated.

[0022] Furthermore, the process of obtaining the first evaluation parameter is as follows: extracting the front image of the feeding vibration platform of the thread rolling machine, importing the preset identification model, performing preset identification model recognition, and after recognizing two preset identifications, marking the center points of the two preset identifications as point A1 and point A2;

[0023] Then, with point A1 as the endpoint, draw a vertical line segment L1 perpendicular to the ground, and with point A2 as the endpoint, draw a vertical line segment L2 perpendicular to the ground;

[0024] The lengths of the line segment L1 and the line segment L2 are measured, and then the length difference between the line segment L1 and the line segment L2 is calculated, that is, the first evaluation parameter is obtained;

[0025] The process of obtaining the second evaluation parameter, the third evaluation parameter and the fourth evaluation parameter is the same as the process of obtaining the first evaluation parameter.

[0026] Furthermore, the process of obtaining the comprehensive evaluation parameters and the process of abnormality determination are as follows:

[0027] extracting a first evaluation parameter, a second evaluation parameter, a third evaluation parameter, and a fourth evaluation parameter;

[0028] Calculate the sum of the first evaluation parameter, the second evaluation parameter, the third evaluation parameter and the fourth evaluation parameter to obtain a comprehensive evaluation parameter;

[0029] When the comprehensive evaluation parameter is greater than the preset value, it means that there is an abnormality.

[0030] Furthermore, the specific processing process of the abnormal environment warning information is as follows: extracting the collected environmental information, the environmental information includes environmental humidity information, environmental temperature information, environmental dust concentration information and environmental vibration force information;

[0031] When the ambient humidity information is greater than the preset value m1 for more than the preset time, an abnormal environment warning message is generated; when the ambient humidity information is greater than or equal to the preset value m2, an abnormal environment warning message is generated;

[0032] When the ambient temperature information is greater than the preset value f1 for more than the preset time, an abnormal environment warning message is generated; when the ambient temperature information is greater than or equal to the preset value f12 for more than the preset time, an abnormal environment warning message is generated;

[0033] When the ambient dust concentration information is greater than the preset value, an abnormal environment warning message is generated;

[0034] When the environmental vibration force information is greater than the preset value, an environmental abnormality warning message is generated.

[0035] Furthermore, the specific process of obtaining the abnormal feeding warning information is as follows:

[0036] Extracting the collected feeding mechanism information, the feeding mechanism information includes feeding speed information and the feeding position height and the discharging position height of the feeding mechanism;

[0037] Calculate the difference between the feed speed information and the preset standard feed speed to obtain the feed assessment difference. When the feed assessment difference exceeds the preset range, a feed abnormality warning message is generated.

[0038] Calculate the difference between the height of the feeding position and the height of the discharging position to obtain the height assessment difference;

[0039] When the height assessment difference is less than the preset value, a feed abnormality warning message is generated.

[0040] Furthermore, the specific process of obtaining the platform shaking warning information is as follows: extracting the collected platform related information, the platform related information including the anchor bolt tightness information of the vibration platform, anchor bolt tightness image information, the running sound of the vibration motor and the equipment shaking amplitude information;

[0041] When the tightness information of the anchor bolts of the vibration platform is less than the preset value, a platform shaking warning message is generated;

[0042] Analyze and process the anchor bolt tightening image information to determine whether there is rust on the anchor bolt surface. If there is rust, extract the rust area. Analyze the rust area to obtain rust assessment parameters. If the rust assessment parameters are abnormal, generate a platform shaking warning message.

[0043] The running sound of the vibration motor is converted into voiceprint information to obtain real-time running voiceprint information, and then the real-time running voiceprint information is compared with the standard running voiceprint of the vibration motor to obtain the voiceprint similarity. When the voiceprint similarity is less than a preset value, a platform shaking warning message is generated;

[0044] When the device shaking amplitude information is greater than the preset value, a platform shaking warning message is generated.

[0045] Furthermore, the specific process of analyzing the corrosion area to obtain the corrosion assessment parameter is as follows: extracting the surface area of ​​the anchor bolt, calculating the difference between the surface area of ​​the anchor bolt and the corrosion area, that is, obtaining the corrosion assessment parameter, when the corrosion assessment parameter is less than the preset value, it indicates that there is an abnormality;

[0046] The process of collecting the equipment shaking amplitude information is as follows: before the feeding vibration platform of the thread rolling machine is operated, a monitoring mark of a preset color is set at a preset position; after the feeding vibration platform of the thread rolling machine is operated, the collected image information is extracted, and the image information is analyzed to obtain the horizontal position change of the monitoring mark of the preset color; the horizontal position change of the monitoring mark of the preset color is monitored in real time within a preset time period; and the maximum value of the horizontal position change of the monitoring mark of the preset color for the preset time period is extracted as the equipment shaking amplitude information.

[0047] Furthermore, the specific processing process of the production warning information is as follows: extracting the collected production information, the production information including real-time output information and real-time yield rate information;

[0048] Then collect the feed speed information. When the feed speed information is greater than the preset value, but the real-time output information is less than the preset value, a production warning message is generated;

[0049] When the real-time yield rate is less than the preset value, a production warning message is generated.

[0050] Compared with the prior art, the present invention has the following advantages: the intelligent monitoring system for screw processing realizes intelligent real-time monitoring of the levelness of the feeding vibration platform of the screw processing thread rolling machine by generating platform levelness supervision information, which can improve production efficiency and stability, ensure product quality, and extend the service life of equipment. By generating environmental abnormality warning information, it can timely discover environmental abnormalities to avoid screw adhesion caused by excessive humidity affecting production efficiency and production quality, equipment failure caused by abnormal temperature and abnormal vibration caused by other equipment in the vibration platform and its surrounding environment may resonate due to similar vibration frequencies, resulting in equipment damage or performance degradation. By generating feed abnormality warning information, it can timely discover The problems existing in the feeding mechanism can be solved by comprehensively monitoring the feeding speed, feed port height and discharge port height to ensure that the feeding vibration platform of the thread rolling machine operates in the best condition, thereby improving the production quality of the screws. Through the generated platform shaking warning information, it can be timely discovered whether there is abnormal shaking of the feeding vibration platform of the thread rolling machine during the screw processing process. Abnormal shaking is often a precursor to equipment failure. Through real-time monitoring, potential fault points can be discovered and handled in time to avoid damage to the equipment due to excessive shaking, thereby ensuring the stable operation of the production line. The system conducts a more comprehensive intelligent monitoring of the feeding vibration platform of the thread rolling machine during the screw processing process, discovers and eliminates abnormalities in time, ensures stable production, and makes the system more worthy of promotion and use. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Figure 1 It is a system block diagram of the present invention. DETAILED DESCRIPTION

[0052] The following is a detailed description of an embodiment of the present invention. This embodiment is implemented on the premise of the technical solution of the present invention, and a detailed implementation method and a specific operation process are given, but the protection scope of the present invention is not limited to the following embodiment.

[0053] like Figure 1 As shown, this embodiment provides a technical solution: an intelligent monitoring system for screw processing, comprising:

[0054] An image information acquisition module, which is used to acquire image information of the feeding vibration platform of the thread rolling machine during screw processing;

[0055] An environmental information collection module is used to collect environmental information of the feeding vibration platform of the thread rolling machine during screw processing;

[0056] A feeding information collection module is used to collect information about the feeding mechanism in the feeding vibration platform of the thread rolling machine during screw processing;

[0057] Platform information collection module, which is used to collect platform-related information of the feeding vibration platform of the thread rolling machine during screw processing;

[0058] Production information collection module, which is used to collect production information of the feeding vibration platform of the thread rolling machine during screw processing;

[0059] Data processing module: The data processing module is used to process image information, environment information, feeding mechanism information, platform related information and production information, and obtain platform level supervision information, environment abnormality warning information, feeding abnormality warning information, platform shaking warning information and production warning information;

[0060] The information sending module is used to send the platform levelness supervision information, environmental abnormality warning information, feed abnormality warning information, platform shaking warning information and production warning information to a preset receiving terminal after the above information is generated.

[0061] The specific processing process of the platform levelness supervision information is as follows: extracting the collected image information, which is the image information of the feeding vibration platform of the thread rolling machine collected from four directions: front, rear, left and right;

[0062] After the feeding vibration platform of the thread rolling machine is installed, two preset marks are set on each surface thereof, which are on the same horizontal plane and have a spacing greater than a preset distance;

[0063] Extracting the front image of the feeding vibration platform of the thread rolling machine, and processing it to obtain the first evaluation parameter;

[0064] The image directly behind the feeding vibration platform of the thread rolling machine is extracted and processed to obtain the second evaluation parameter;

[0065] The left image of the feeding vibration platform of the thread rolling machine is extracted and processed to obtain the third evaluation parameter;

[0066] The right side image of the feeding vibration platform of the thread rolling machine is extracted and processed to obtain the fourth evaluation parameter;

[0067] Analyze the first evaluation parameter, the second evaluation parameter, the third evaluation parameter, and the fourth evaluation parameter to obtain a comprehensive evaluation parameter;

[0068] When the comprehensive assessment parameters are abnormal, platform level supervision information is generated.

[0069] The horizontality monitoring of the feeding vibration platform of the thread rolling machine in the screw production process has many benefits including:

[0070] Improve production efficiency and stability: Reduce downtime: Keeping the vibration platform level can ensure smooth feeding of the thread rolling machine, avoid problems such as material jamming and breaking caused by uneven vibration, thereby reducing downtime caused by faults and improving production efficiency.

[0071] Optimize production process: Level monitoring can help to detect problems with the vibration platform in time and make timely adjustments to ensure the continuity and stability of the production process.

[0072] Ensure product quality: Reduce defective rate: Insufficient levelness of the vibration platform may lead to uneven feeding, which in turn affects the thread rolling effect, such as uneven thread depth, inaccurate pitch, etc., and ultimately increase the defective rate. Levelness monitoring helps to reduce such problems and improve product quality. Improve product consistency: Maintaining the levelness of the vibration platform can ensure that each screw receives the same treatment during the thread rolling process, thereby improving product consistency and reliability.

[0073] Extend equipment life: Reduce mechanical wear: The unbalanced vibration of the vibration platform will accelerate the wear of mechanical parts, such as bearings, transmission devices, etc. Level monitoring helps to reduce this unnecessary wear and extend the service life of the equipment.

[0074] Reduce maintenance costs: Through level monitoring, potential problems can be discovered and dealt with in a timely manner, preventing small problems from turning into major failures, thereby reducing equipment maintenance costs.

[0075] Improve operational safety: Reduce safety hazards: Unbalanced vibration platforms may cause safety accidents, such as excessive vibration causing equipment to topple over, personnel injuries, etc. Level monitoring helps ensure that the vibration platform operates within a safe range and reduces safety hazards.

[0076] Improve operator comfort: The smooth operation of the vibration platform can reduce operator fatigue, improve the comfort of the working environment, and thus improve work efficiency and employee job satisfaction.

[0077] In summary, monitoring the levelness of the feeding vibration platform of the thread rolling machine in the screw production process has many benefits, including improving production efficiency and stability, ensuring product quality, extending equipment life, improving operational safety, and complying with industry standards and regulatory requirements.

[0078] The process of obtaining the first evaluation parameter is as follows: extracting the front image of the feeding vibration platform of the thread rolling machine, importing the preset identification model, performing preset identification model recognition, and after recognizing two preset identifications, marking the center points of the two preset identifications as point A1 and point A2;

[0079] Then, with point A1 as the endpoint, draw a vertical line segment L1 perpendicular to the ground, and with point A2 as the endpoint, draw a vertical line segment L2 perpendicular to the ground;

[0080] The lengths of the line segment L1 and the line segment L2 are measured, and then the length difference between the line segment L1 and the line segment L2 is calculated, that is, the first evaluation parameter is obtained;

[0081] The process of obtaining the second evaluation parameter, the third evaluation parameter and the fourth evaluation parameter is the same as the process of obtaining the first evaluation parameter.

[0082] Furthermore, the process of obtaining the comprehensive evaluation parameters and the process of abnormality determination are as follows:

[0083] extracting a first evaluation parameter, a second evaluation parameter, a third evaluation parameter, and a fourth evaluation parameter;

[0084] Calculate the sum of the first evaluation parameter, the second evaluation parameter, the third evaluation parameter and the fourth evaluation parameter to obtain a comprehensive evaluation parameter;

[0085] When the comprehensive evaluation parameter is greater than the preset value, it means that there is an abnormality;

[0086] Through the above process, more accurate relevant parameters can be obtained, which can be guaranteed.

[0087] The specific processing process of the abnormal environment warning information is as follows: extracting the collected environmental information, the environmental information includes environmental humidity information, environmental temperature information, environmental dust concentration information and environmental vibration force information;

[0088] When the ambient humidity information is greater than the preset value m1 for more than the preset time, an abnormal environment warning message is generated; when the ambient humidity information is greater than or equal to the preset value m2, an abnormal environment warning message is generated;

[0089] When the ambient temperature information is greater than the preset value f1 for more than the preset time, an abnormal environment warning message is generated; when the ambient temperature information is greater than or equal to the preset value f12 for more than the preset time, an abnormal environment warning message is generated;

[0090] When the ambient dust concentration information is greater than the preset value, an abnormal environment warning message is generated;

[0091] When the environmental vibration force information is greater than the preset value, an environmental abnormality warning message is generated;

[0092] Monitoring the ambient humidity, ambient temperature and ambient vibration force of the feeding vibration platform of the thread rolling machine in the screw production process has significant benefits, among which the benefits of ambient humidity monitoring are: Preventing equipment corrosion: High humidity environment easily causes rust and corrosion of metal parts, affecting the normal operation and life of the equipment. By monitoring the ambient humidity, it is possible to detect and take measures to reduce the humidity in time to protect the equipment from corrosion.

[0093] Ensure electrical safety: Excessive humidity can also cause electrical components to become damp, increasing the risk of short circuits and failures. Environmental humidity monitoring helps ensure the safe and stable operation of electrical systems.

[0094] Improve production efficiency: Appropriate humidity conditions help keep equipment in normal operation, reduce downtime caused by humidity problems, and thus improve production efficiency.

[0095] Benefits of ambient temperature monitoring: Ensure normal operation of equipment: Different equipment has different requirements for ambient temperature. Too high or too low temperature may affect the performance and life of the equipment. By monitoring the ambient temperature, the temperature conditions can be adjusted in time to ensure that the equipment operates in the best condition.

[0096] Prevent thermal stress issues: Temperature changes may cause thermal stress in equipment components, which may lead to deformation or damage. Ambient temperature monitoring can help detect and prevent such issues in a timely manner.

[0097] Optimize energy utilization: In some cases, by properly controlling the ambient temperature, the energy consumption of the equipment can be reduced and the energy utilization efficiency can be improved.

[0098] Benefits of environmental vibration force monitoring: Preventing resonance: The vibration platform and other equipment in its surroundings may resonate due to similar vibration frequencies, causing equipment damage or performance degradation. By monitoring the environmental vibration force, you can detect and take measures to avoid the occurrence of resonance in a timely manner.

[0099] Evaluate equipment stability: Vibration force monitoring helps evaluate the stability and reliability of the vibration platform and provides data support for equipment maintenance and servicing.

[0100] Optimize vibration parameters: According to the environmental vibration force monitoring results, the vibration parameters of the vibration platform (such as frequency, amplitude, etc.) can be adjusted to optimize the feeding effect and production efficiency.

[0101] This can improve product quality: By comprehensively monitoring the ambient humidity, temperature and vibration force, it can ensure that the feeding vibration platform of the thread rolling machine operates in the best environment, thereby improving the production quality and consistency of the screws.

[0102] Reduce maintenance costs: Timely detection and resolution of environmental problems can reduce downtime and repair costs caused by equipment failures, thereby reducing maintenance costs.

[0103] Enhance production safety: Monitoring environmental parameters helps prevent safety accidents caused by equipment failure or improper operation, and ensures the safety of production personnel.

[0104] Monitoring the ambient humidity, ambient temperature and ambient vibration force of the feeding vibration platform of the thread rolling machine during the screw production process is of great significance for ensuring the normal operation of the equipment, improving production efficiency, ensuring product quality and reducing maintenance costs.

[0105] The specific process of obtaining the abnormal feeding warning information is as follows:

[0106] Extracting the collected feeding mechanism information, the feeding mechanism information includes feeding speed information and the feeding position height and the discharging position height of the feeding mechanism;

[0107] Calculate the difference between the feed speed information and the preset standard feed speed to obtain the feed assessment difference. When the feed assessment difference exceeds the preset range, a feed abnormality warning message is generated.

[0108] Calculate the difference between the height of the feeding position and the height of the discharging position to obtain the height assessment difference;

[0109] When the height assessment difference is less than the preset value, a feed abnormality warning message is generated.

[0110] Monitor the feeding speed of the feeding vibration platform of the thread rolling machine, the height of the feeding port of the feeding mechanism, and the height of the feeding port of the feeding mechanism during the screw production process:

[0111] Among the benefits of feed speed monitoring: Improve production efficiency: By real-time monitoring of the feed speed, it can ensure that the thread rolling machine is always in the best working condition, avoiding production bottlenecks caused by feeding too fast or too slow, thereby improving overall production efficiency.

[0112] Optimize production process: Monitoring of feed speed helps to timely identify bottlenecks in the production process, provide data support for production line optimization, and further improve production efficiency and flexibility.

[0113] Reduce waste: Reasonable feeding speed can reduce the damage or waste of screws caused by overspeed or blockage, and reduce production costs.

[0114] Benefits of monitoring the feed port height of the feeding mechanism: Ensure smooth feeding: Monitoring the feed port height helps ensure that the screws can enter the vibration platform smoothly, avoiding problems such as jamming or leakage caused by improper height.

[0115] Adapt to screws of different specifications: By adjusting the height of the feed port, it can adapt to screws of different specifications and sizes, improving the flexibility and adaptability of the production line.

[0116] Reduce manual intervention: Automated monitoring and adjustment of the feed port height can reduce the frequency and difficulty of manual adjustments and reduce labor costs.

[0117] Benefits of monitoring the height of the discharge port of the feeding mechanism: Optimizing the discharge effect: Monitoring the height of the discharge port helps ensure that the screws can smoothly enter the next process when leaving the vibration platform, avoiding accumulation or scattering problems caused by improper height.

[0118] Improve production accuracy: Reasonable discharge port height can ensure that the screw maintains a stable posture and speed during discharge, and improve the accuracy and consistency of subsequent processing procedures.

[0119] Reduce failure rate: Monitoring the height of the discharge port can also promptly detect and resolve potential blockage or material jamming problems, reduce equipment failure rate, and ensure continuous and stable operation of the production line.

[0120] Improve product quality: By comprehensively monitoring the feed speed, feed port height and discharge port height, it can ensure that the thread rolling machine feed vibration platform operates in the best condition, thereby improving the production quality and consistency of screws.

[0121] Reduce maintenance costs: Timely detection and resolution of potential problems can reduce downtime and repair costs caused by equipment failure, thereby reducing maintenance costs.

[0122] Enhanced production flexibility: Monitoring and adjusting these parameters can adapt to the production needs of screws of different specifications and sizes, improving the flexibility and adaptability of the production line.

[0123] Monitoring the feeding speed of the feeding vibration platform of the thread rolling machine, the height of the feeding port of the feeding mechanism and the height of the feeding port of the feeding mechanism during the screw production process is of great significance for improving production efficiency, optimizing production processes, reducing waste, ensuring product quality, reducing maintenance costs and enhancing production flexibility.

[0124] The specific process of obtaining the platform shaking warning information is as follows: extracting the collected platform related information, the platform related information including the anchor bolt tightness information of the vibration platform, anchor bolt tightness image information, the running sound of the vibration motor and the equipment shaking amplitude information;

[0125] When the tightness information of the anchor bolts of the vibration platform is less than the preset value, a platform shaking warning message is generated;

[0126] Analyze and process the anchor bolt tightening image information to determine whether there is rust on the anchor bolt surface. If there is rust, extract the rust area. Analyze the rust area to obtain rust assessment parameters. If the rust assessment parameters are abnormal, generate a platform shaking warning message.

[0127] The running sound of the vibration motor is converted into voiceprint information to obtain real-time running voiceprint information, and then the real-time running voiceprint information is compared with the standard running voiceprint of the vibration motor to obtain the voiceprint similarity. When the voiceprint similarity is less than a preset value, a platform shaking warning message is generated;

[0128] When the device shaking amplitude information is greater than the preset value, a platform shaking warning message is generated.

[0129] The advantages of monitoring abnormal shaking of the feeding vibration platform of the thread rolling machine during the screw production process include:

[0130] Improve production stability and safety: Prevent equipment failure: Abnormal shaking is often a precursor to equipment failure. Through real-time monitoring, potential fault points can be discovered and handled in a timely manner to avoid equipment damage due to excessive shaking, thereby ensuring the stable operation of the production line.

[0131] Reduce safety risks: Severe shaking may cause equipment parts to loosen or fall off, or even cause safety accidents such as equipment tipping over. Monitoring abnormal shaking can help take timely measures to reduce safety risks and protect the safety of production personnel and equipment.

[0132] Ensure product quality: Reduce defective rate: The shaking of the vibration platform will directly affect the feeding speed and posture of the screw, which in turn affects the thread rolling effect. Abnormal shaking may cause the screw to be misaligned, deformed or the thread is unqualified, increasing the defective rate. By monitoring and controlling the shaking, the feeding stability and consistency of the screw can be ensured, thereby improving product quality.

[0133] Improve production efficiency: The stable vibration platform can ensure that the screws enter the thread rolling machine at a stable speed and posture, improving thread rolling efficiency and production speed. At the same time, reducing downtime and maintenance costs caused by shaking also helps to improve overall production efficiency.

[0134] Optimize equipment performance and maintenance: Adjust equipment parameters: By monitoring abnormal shaking, the specific causes of shaking can be analyzed (such as improper vibration frequency and amplitude settings, wear of equipment components, etc.), and the equipment parameters can be adjusted accordingly to make the vibration platform run in the best condition.

[0135] Guiding equipment maintenance: Abnormal shaking monitoring data can provide an important basis for preventive maintenance and troubleshooting of equipment. According to the monitoring results, targeted maintenance plans can be formulated to replace worn parts in advance and reduce the occurrence of sudden failures.

[0136] Improve the level of intelligence: realize automatic monitoring: by installing sensors and monitoring systems, real-time monitoring and automatic alarm of abnormal shaking of the vibration platform can be realized. This can not only reduce the burden of manual monitoring, but also improve the accuracy and timeliness of monitoring.

[0137] Integration into production management system: Abnormal shaking monitoring data can be integrated into the production management system and analyzed and managed together with other production data. This helps enterprises realize digital and intelligent management of the production process and improve production efficiency and product quality.

[0138] Monitoring the abnormal shaking of the feeding vibration platform of the thread rolling machine during the screw production process is of great significance for improving production stability and safety, ensuring product quality, optimizing equipment performance and maintenance, and improving the level of intelligence.

[0139] Furthermore, the specific process of analyzing the corrosion area to obtain the corrosion assessment parameter is as follows: extracting the surface area of ​​the anchor bolt, calculating the difference between the surface area of ​​the anchor bolt and the corrosion area, that is, obtaining the corrosion assessment parameter, when the corrosion assessment parameter is less than the preset value, it indicates that there is an abnormality;

[0140] The process of collecting the equipment shaking amplitude information is as follows: before the feeding vibration platform of the thread rolling machine is operated, a monitoring mark of a preset color is set at a preset position; after the feeding vibration platform of the thread rolling machine is operated, the collected image information is extracted, and the image information is analyzed to obtain the horizontal position change of the monitoring mark of the preset color; the horizontal position change of the monitoring mark of the preset color is monitored in real time within a preset time period; and the maximum value of the horizontal position change of the monitoring mark of the preset color for the preset time period is extracted as the equipment shaking amplitude information.

[0141] The specific processing process of the production warning information is as follows: extracting the collected production information, the production information includes real-time output information and real-time yield rate information;

[0142] Then collect the feed speed information. When the feed speed information is greater than the preset value, but the real-time output information is less than the preset value, a production warning message is generated;

[0143] When the real-time yield rate is less than the preset value, a production warning message is generated.

[0144] Real-time monitoring can detect equipment failures or potential problems in a timely manner, and take measures to repair or adjust them in advance. This helps to reduce downtime caused by equipment failure and improve the continuity and stability of the production line; by analyzing the monitoring data, the actual operation and production efficiency of the production line can be understood. This helps companies adjust production plans according to actual conditions, arrange production tasks reasonably, and improve production efficiency and resource utilization. Monitoring data can also help companies understand the operating status and performance of equipment. By optimizing equipment configuration and usage, the utilization rate and capacity of equipment can be improved, and production efficiency can be further improved.

[0145] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0146] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0147] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present invention.

Claims

1. An intelligent monitoring system for screw processing, characterized in that: It includes image information acquisition module, environment information acquisition module, feed information acquisition module, production information acquisition module, platform information acquisition module, data processing module and information sending module; The image information acquisition module is used to acquire image information of the feeding vibration platform of the thread rolling machine during screw processing; The environmental information collection module is used to collect the environmental information of the feeding vibration platform of the thread rolling machine during the screw processing; The feeding information collection module is used to collect the feeding mechanism information in the feeding vibration platform of the thread rolling machine during the screw processing; The platform information acquisition module is used to collect platform-related information of the feeding vibration platform of the thread rolling machine during screw processing; The production information collection module is used to collect production information of the feeding vibration platform of the thread rolling machine during the screw processing; The data processing module is used to process image information, environment information, feed mechanism information, platform related information and production information, and obtain platform level supervision information, environment abnormality warning information, feed abnormality warning information, platform shaking warning information and production warning information; The information sending module is used to send the platform levelness supervision information, environmental abnormality warning information, feed abnormality warning information, platform shaking warning information and production warning information to a preset receiving terminal after the above information is generated; The specific processing process of the platform levelness supervision information is as follows: extracting the collected image information, which is the image information of the feeding vibration platform of the thread rolling machine collected from four directions: front, rear, left and right; After the feeding vibration platform of the thread rolling machine is installed, two preset marks are set on each surface thereof, which are on the same horizontal plane and have a spacing greater than a preset distance; Extracting the front image of the feeding vibration platform of the thread rolling machine, and processing it to obtain the first evaluation parameter; The image directly behind the feeding vibration platform of the thread rolling machine is extracted and processed to obtain the second evaluation parameter; The left image of the feeding vibration platform of the thread rolling machine is extracted and processed to obtain the third evaluation parameter; The right side image of the feeding vibration platform of the thread rolling machine is extracted and processed to obtain the fourth evaluation parameter; Analyze the first evaluation parameter, the second evaluation parameter, the third evaluation parameter, and the fourth evaluation parameter to obtain a comprehensive evaluation parameter; When the comprehensive assessment parameters are abnormal, platform level supervision information is generated.

2. The intelligent monitoring system for screw processing according to claim 1, characterized in that: The process of obtaining the first evaluation parameter is as follows: extracting the front image of the feeding vibration platform of the thread rolling machine, importing the preset identification model, performing preset identification model recognition, and after recognizing two preset identifications, marking the center points of the two preset identifications as point A1 and point A2; Then, with point A1 as the endpoint, draw a vertical line segment L1 perpendicular to the ground, and with point A2 as the endpoint, draw a vertical line segment L2 perpendicular to the ground; The lengths of the line segment L1 and the line segment L2 are measured, and then the length difference between the line segment L1 and the line segment L2 is calculated, that is, the first evaluation parameter is obtained; The process of obtaining the second evaluation parameter, the third evaluation parameter and the fourth evaluation parameter is the same as the process of obtaining the first evaluation parameter.

3. The intelligent monitoring system for screw processing according to claim 1, characterized in that: The process of obtaining the comprehensive evaluation parameters and the abnormality determination process are as follows: extracting a first evaluation parameter, a second evaluation parameter, a third evaluation parameter, and a fourth evaluation parameter; Calculate the sum of the first evaluation parameter, the second evaluation parameter, the third evaluation parameter and the fourth evaluation parameter to obtain a comprehensive evaluation parameter; When the comprehensive evaluation parameter is greater than the preset value, it means that there is an abnormality.

4. The intelligent monitoring system for screw processing according to claim 1, characterized in that: The specific processing process of the abnormal environment warning information is as follows: extracting the collected environmental information, the environmental information includes environmental humidity information, environmental temperature information, environmental dust concentration information and environmental vibration force information; When the ambient humidity information is greater than the preset value m1 for more than the preset time, an abnormal environment warning message is generated; when the ambient humidity information is greater than or equal to the preset value m2, an abnormal environment warning message is generated; When the ambient temperature information is greater than the preset value f1 for more than the preset time, an abnormal environment warning message is generated; when the ambient temperature information is greater than or equal to the preset value f12 for more than the preset time, an abnormal environment warning message is generated; When the ambient dust concentration information is greater than the preset value, an abnormal environment warning message is generated; When the environmental vibration force information is greater than the preset value, an environmental abnormality warning message is generated.

5. The intelligent monitoring system for screw processing according to claim 1, characterized in that: The specific process of obtaining the abnormal feeding warning information is as follows: Extracting the collected feeding mechanism information, the feeding mechanism information includes feeding speed information and the feeding position height and the discharging position height of the feeding mechanism; Calculate the difference between the feed speed information and the preset standard feed speed to obtain the feed assessment difference. When the feed assessment difference exceeds the preset range, a feed abnormality warning message is generated. Calculate the difference between the height of the feeding position and the height of the discharging position to obtain the height assessment difference; When the height assessment difference is less than the preset value, a feed abnormality warning message is generated.

6. The intelligent monitoring system for screw processing according to claim 1, characterized in that: The specific process of obtaining the platform shaking warning information is as follows: extracting the collected platform related information, the platform related information including the anchor bolt tightness information of the vibration platform, anchor bolt tightness image information, the running sound of the vibration motor and the equipment shaking amplitude information; When the tightness information of the anchor bolts of the vibration platform is less than the preset value, a platform shaking warning message is generated; Analyze and process the anchor bolt tightening image information to determine whether there is rust on the anchor bolt surface. If there is rust, extract the rust area. Analyze the rust area to obtain rust assessment parameters. If the rust assessment parameters are abnormal, generate a platform shaking warning message. The running sound of the vibration motor is converted into voiceprint information to obtain real-time running voiceprint information, and then the real-time running voiceprint information is compared with the standard running voiceprint of the vibration motor to obtain the voiceprint similarity. When the voiceprint similarity is less than a preset value, a platform shaking warning message is generated; When the device shaking amplitude information is greater than the preset value, a platform shaking warning message is generated.

7. The intelligent monitoring system for screw processing according to claim 6, characterized in that: The specific process of analyzing the corrosion area to obtain the corrosion assessment parameter is as follows: extract the surface area of ​​the anchor bolt, calculate the difference between the surface area of ​​the anchor bolt and the corrosion area, that is, obtain the corrosion assessment parameter. When the corrosion assessment parameter is less than the preset value, it indicates that there is an abnormality; The process of collecting the equipment shaking amplitude information is as follows: before the feeding vibration platform of the thread rolling machine is operated, a monitoring mark of a preset color is set at a preset position; after the feeding vibration platform of the thread rolling machine is operated, the collected image information is extracted, and the image information is analyzed to obtain the horizontal position change of the monitoring mark of the preset color; the horizontal position change of the monitoring mark of the preset color is monitored in real time within a preset time period; and the maximum value of the horizontal position change of the monitoring mark of the preset color for the preset time period is extracted as the equipment shaking amplitude information.

8. The intelligent monitoring system for screw processing according to claim 1, characterized in that: The specific processing process of the production warning information is as follows: extracting the collected production information, the production information includes real-time output information and real-time yield rate information; Then collect the feed speed information. When the feed speed information is greater than the preset value, but the real-time output information is less than the preset value, a production warning message is generated; When the real-time yield rate is less than the preset value, a production warning message is generated.

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