Intelligent five-axis machine tool cutter life prediction and management system

Abstract

The invention relates to an intelligent five-axis machine tool cutter service life prediction and management system, which comprises a system end and an equipment end, the equipment end is composed of a machine tool cutter mounting frame, a cutter head, a cutter detector, a temperature sensor, a vibration sensor and a cutting force sensor are mounted on the equipment end, and the system end comprises a processor connected with a monitoring module, a detection module, a prediction module and a control module. The monitoring module collects working data of a tool bit, the detection module evaluates abrasion, the prediction module calculates the remaining life, the control module manages a machine tool and a detector, the tool mounting frame is composed of a main support, a rotating disc, a mounting table, a motor and a tool mounting shaft, and the tool mounting frame further comprises a servo motor and a transmission belt and achieves real-time monitoring and analysis of the working state of a tool. According to the use condition and monitoring data of the cutter, the remaining service life of the cutter is evaluated, more accurate detection nodes and alarm nodes are set for subsequent use of the cutter, and it is ensured that the cutter does not exceed the optimal service life in the use process.

Description

Technical Field

[0001] The present invention relates to an intelligent five-axis machine tool tool life prediction and management system, and in particular to an intelligent five-axis machine tool tool life prediction and management system applied to a tool management system. Background Art

[0002] Existing tool life prediction and management systems typically rely on a variety of technologies, including sensor technology, data analysis, machine learning, and the Internet of Things (IoT). These systems assess tool wear and predict tool remaining life by monitoring machine and tool performance parameters such as cutting force, vibration, temperature, and sound in real time. Sensor technology is used to collect these critical data, while data analysis and machine learning algorithms are used to process and interpret the data to identify tool wear patterns and trends.

[0003] Chinese invention patent CN109934424A discloses a tool life prediction method and intelligent tool management system, which includes the following steps: S1: set n parameters that affect tool life, and select m groups of tool data to form a training data set, each group of tool data includes n parameter values ​​corresponding to each parameter and tool life value; S2: establish a tool life prediction model, use each parameter value in the training data set as input data, and the tool life value as output data, train the tool life prediction model, and determine the parameters of the tool life prediction model; S3: input the data of the tool to be tested into the optimal tool life prediction model, and determine the predicted value of the tool life according to the output of the model. The invention applies the tool life prediction model to the intelligent tool management system, which can effectively improve the accuracy of the prediction of the remaining tool life.

[0004] Existing machine tools are not accurate enough in assessing tool wear and predicting remaining life, and lack effective real-time monitoring and management mechanisms during tool use. This may lead to excessive tool wear, thereby affecting machine tool processing efficiency and tool use efficiency, and may even cause production accidents and economic losses. Summary of the invention

[0005] In view of the above-mentioned prior art, the technical problem to be solved by the present invention is that the existing machine tools are not accurate enough in assessing the tool wear status and predicting the remaining life, and lack effective real-time monitoring and management mechanisms during the use of the tools, which may lead to excessive wear of the tools, thereby affecting the machine tool processing efficiency and tool use efficiency, and may even cause production accidents and economic losses.

[0006] In order to solve the above problems, the present invention provides an intelligent five-axis machine tool tool life prediction and management system, including a system end and a device end; the device end includes a tool mounting frame installed on the machine tool, and a tool head and a tool detector are installed on the tool mounting frame; The system end includes a processor, to which a monitoring module, a detection module, a prediction module and a control module are connected; The monitoring module is used to collect monitoring data of the tool head on the tool mounting rack when it is working. The monitoring data includes the number of times the tool is used, the use time, the working temperature, the vibration data during operation, and the cutting force data during operation; The detection module is used to evaluate the wear condition of the cutter head according to the detection result of the cutter detector; The prediction module evaluates the remaining service life of the tool based on the monitoring data and the detection results of the detection module. The control module is used to control the operation of the machine tool and the tool detector; The tool mounting frame is equipped with a temperature sensor, a vibration sensor and a cutting force sensor that match the tool; The tool mounting frame comprises a main bracket, the lower end of the main bracket is rotatably connected to a rotating disk, a mounting platform is fixedly connected to the rotating disk, a motor and a tool mounting shaft are respectively installed at the upper and lower ends of the mounting platform, and the power output end of the motor is fixedly connected to the tool mounting shaft; a servo motor is installed at the upper end of the main bracket, and a transmission belt is connected between the power output end of the servo motor and the rotating disk; The tool detectors are arranged in pairs at the side ends of the mounting table. Self-resetting slide rails matching the tool detectors are installed at both ends of the mounting table. An image collector and a detection probe are installed at the detection end of the tool detector. Data receivers matching the tool detectors are installed on both sides of the upper end of the main bracket. A docking telescopic rod is installed on the data receiver. A docking socket is provided at the top of the tool detector, and a docking plug matching the docking socket is installed at the movable end of the docking telescopic rod.

[0007] In the above-mentioned intelligent five-axis machine tool tool life prediction and management system, it is possible to evaluate the remaining service life of the tool based on the tool usage and monitoring data, set more accurate detection nodes and alarm nodes for subsequent tool use, and perform regular automatic detection to update the service life assessment.

[0008] As a further improvement of the present application, the tool detector includes a shell, and one end of the shell close to the tool mounting shaft is rotatably connected to a detection arm, and the detection arm rotates and extends toward the tool head installed at the tool mounting shaft.

[0009] As a further improvement of the present application, the detection arm includes a rotating arm, which is rotatably connected to the shell through a hollow rotating shaft, a stepper motor for driving the hollow rotating shaft to rotate is installed on the shell, a movable arm is plugged into the rotating arm, a corrugated air pipe connected to the hollow rotating shaft is installed on the movable arm, an inflation interface communicating with the hollow rotating shaft is installed at the top of the shell, and an inflation joint is installed at the movable end of the docking telescopic rod.

[0010] As a further improvement of the present application, the self-resetting slide rail includes a slide rail installed on a mounting table, a slide table is slidably connected to the slide rail, the shell is fixedly connected to the slide table, and a compression spring is connected between the slide table and the bottom end of the slide rail.

[0011] As another improvement of the present application, a laser receiver is installed at the bottom end of the electric motor, and a laser transmitter matching the laser receiver is installed at the bottom end of the servo motor.

[0012] As another improvement supplement of the present application, before the tool detector performs detection work, the servo motor drives the mounting table to reset so that the tool mounting axis is vertically facing the ground, and then the tool detector is controlled to dock with the docking telescopic rod so that the tool detector is pushed to the side end of the cutter head, and then the stepper motor is controlled to work to rotate the detection arm until the detection probe and image collector at the top of the detection arm are close to the cutter head.

[0013] As another improved supplement of the present application, the image collector includes a high-definition camera and an infrared image acquisition device, the detection probe includes a temperature detection probe, and the image collector and the detection probe are respectively arranged on two tool detectors.

[0014] As another improvement of the present application, the prediction module sets a detection node or an alarm node according to the remaining service life; the detection nodes are evenly set within the remaining service life of the tool, and the alarm node is set at a set time interval from the end of the remaining service life of the tool head; When the cutter head works to the detection node and the alarm node, the tool detector will detect the cutter head.

[0015] As another improvement of the present application, an alarm module is connected to the processor. When the monitoring module detects that the remaining service life of the cutter head is less than a set value and the monitoring data is not within the set value range, the monitoring module sends a signal to the alarm module and the control module. The alarm module performs an audible and visual alarm and sends an alarm message, and the control module controls the machine tool to shut down.

[0016] In summary, this solution monitors and analyzes the working status of the tool in real time, evaluates the remaining service life of the tool based on the tool usage and monitoring data, sets more accurate detection nodes and alarm nodes for subsequent tool use, and regularly performs automatic detection to update the service life assessment, thereby ensuring that the tool does not exceed its optimal service life during use and avoiding production accidents and economic losses caused by excessive tool wear. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a block diagram of the tool life prediction and management system of the first and second implementation modes of this application; Figure 2 A three-dimensional diagram of a machine tool according to the first and second embodiments of the present application; Figure 3 for Figure 2 The structural diagram at A in the middle; Figure 4 It is a partial cross-sectional view of the tool mounting frame of the first and second embodiments of the present application; Figure 5 This is a cross-sectional view of the tool detector in the first and second embodiments of the present application when working; Figure 6 for Figure 5 The structural diagram at B in the middle; Figure 7 It is a schematic diagram of the back of the machine tool of the first and second embodiments of the present application; Figure 8 This is the operation logic diagram of the tool life prediction and management system of the first and second implementation modes of the present application.

[0018] Description of the numbers in the figure: 1 tool mounting frame, 11 main bracket, 12 rotating disk, 13 mounting table, 14 motor, 15 tool mounting shaft, 16 servo motor, 2 tool detector, 21 housing, 22 detection arm, 221 rotating arm, 222 hollow rotating shaft, 223 movable arm, 224 corrugated air pipe, 3 data receiver, 4 docking telescopic rod, 5 self-resetting slide rail. DETAILED DESCRIPTION

[0019] The following describes two implementation modes of the present application in detail with reference to the accompanying drawings.

[0020] The first implementation method: Figure 1-8 FIG. 1 shows an intelligent five-axis machine tool tool life prediction and management system, including a system end and a device end; the device end includes a tool mounting frame 1 installed on the machine tool, and a tool head and a tool detector 2 are installed on the tool mounting frame 1; The system end includes a processor, to which a monitoring module, a detection module, a prediction module and a control module are connected; The monitoring module is used to collect monitoring data of the tool head on the tool mounting frame 1 when it is working, and the monitoring data includes the number of times the tool is used, the use time, the working temperature, the vibration data during operation, and the cutting force data during operation; The detection module is used to evaluate the wear condition of the cutter head according to the detection result of the cutter detector 2; an image analysis unit is provided in the detection module, the cutter detector 2 collects the cutter image, and the detection module learns the wear condition of the cutter head through image analysis; The prediction module evaluates the remaining service life of the tool based on the monitoring data and the detection results of the detection module. The remaining service life of the tool is equivalent to the remaining cutting time of the tool; A technician in this field sets a prior art tool remaining service life estimation program in the prediction module, and estimates the remaining service life of the tool by combining the wear condition of the tool head, cutting force monitoring data, cutting temperature monitoring and vibration monitoring data, and changes in cutting conditions; The specific estimation method or procedure of the remaining service life of the tool is set by the technicians in this field by selecting appropriate existing technologies; the method or procedure of the prediction module for predicting the remaining service life of the tool does not belong to the protection scope of this solution; The prediction module sets the detection node or the alarm node according to the remaining service life; the detection nodes are evenly set within the remaining service life of the tool, and the alarm node is set at a set time interval from the end of the remaining service life of the tool head. The prediction module is set according to the preset program and the remaining service life of the tool. For example, if the remaining service life of the tool head is 6 hours, the alarm node is set at the time point of 1 hour of the remaining service life, and the detection node is set at the time points of 4 hours, 3 hours and 2 hours of the remaining service life; When the cutter head works to the detection node and the alarm node, the tool detector 2 performs detection work on the cutter head.

[0021] The control module is used to control the operation of the machine tool and the tool detector 2, specifically regulating the machine tool switch and the operating parameters of each device therein; An alarm module is connected to the processor. When the monitoring module detects that the remaining service life of the cutter head is less than the set value and the monitoring data is not within the set value range, the monitoring module sends a signal to the alarm module and the control module. The alarm module performs an audible and visual alarm and sends an alarm message, and the control module controls the machine tool to stop.

[0022] The tool mounting frame 1 is equipped with a temperature sensor, a vibration sensor and a cutting force sensor that match the tool; the temperature sensor, the vibration sensor and the cutting force sensor are used to collect the cutting force monitoring data, the cutting temperature monitoring data and the vibration monitoring data of the tool on the tool mounting shaft 15 when the tool is working; the technicians in this field use appropriate temperature sensors, vibration sensors and cutting force sensors to install on the tool mounting frame 1 to ensure that the tool is monitored when working; The tool mounting frame 1 includes a main bracket 11, the lower end of the main bracket 11 is rotatably connected to a rotating disk 12, the rotating disk 12 is fixedly connected to a mounting platform 13, the upper and lower ends of the mounting platform 13 are respectively mounted with a motor 14 and a tool mounting shaft 15, and the power output end of the motor 14 is fixedly connected to the tool mounting shaft 15; a servo motor 16 is mounted on the upper end of the main bracket 11, and a transmission belt is connected between the power output end of the servo motor 16 and the rotating disk 12; a laser receiver is mounted on the bottom end of the motor 14, and a laser transmitter matching the laser receiver is mounted on the bottom end of the servo motor 16, and the laser receiver and the laser transmitter are used for positioning and calibration when the mounting platform 13 is rotated and reset.

[0023] The tool detectors 2 are arranged in pairs at the side ends of the mounting platform 13. Self-resetting slide rails 5 matching the tool detectors 2 are installed at both ends of the mounting platform 13. The self-resetting slide rails 5 include slide rails installed on the mounting platform 13, and a slide table is slidably connected to the slide rails. The housing 21 is fixedly connected to the slide table, and a compression spring is connected between the slide table and the bottom end of the slide rail.

[0024] This solution detects the tool status through temperature sensors, vibration sensors and cutting force sensors when the tool is working. When any detection data exceeds the set value, the tool head is quickly reset, and then the docking telescopic rod 4 is controlled to dock with the tool detector 2, and the tool detector 2 is pushed down to the side end of the tool head, and then the detector tool detector 2 is adjusted so that its detection end is close to the position of the tool head, and then image recognition and detailed detection are performed; During the adjustment process of the tool detector 2, since the tool detector 2 is connected to the data analysis end, power supply and data transmission during detection are realized; Before the tool detector 2 performs detection work, the servo motor 16 drives the mounting table 13 to reset so that the tool mounting axis 15 is vertically facing the ground, and then controls the tool detector 2 to dock with the docking telescopic rod 4, so that the tool detector 2 is pushed to the side end of the tool head, and then controls the stepper motor to work to rotate the detection arm 22 until the detection probe and image collector at the top of the detection arm 22 are close to the tool head.

[0025] The detection module analyzes the image and temperature distribution data collected at the cutter head to analyze the wear condition of the cutter head; and determines whether the cutter head can continue to be used according to the wear condition; If the analysis result determines that the cutter head can continue to be used, the remaining service life of the cutter head is evaluated by combining the various monitoring data when the cutter head is working and the detection result of the detector tool detector 2. When the remaining service life is less than the set value, the system alarms to remind you to replace the cutter head; If the remaining service life is greater than the set value, the prediction module sets a detection node or an alarm node according to the remaining service life; when the cutter head continues to be used normally until the detection node, it is detected again and the predicted remaining service life of the cutter head is updated, and then the detection node or the alarm node is set according to the latest updated remaining service life of the cutter head; When the cutter head continues to be used normally until the alarm point, the test is performed again and the test results are recorded. The system alarms and the cutter head is replaced. Then, the normal service life of the cutter head of this type under the same working conditions is evaluated according to the test results, and then the test nodes for the subsequent use of the cutter head of this type are set according to the service life; This allows for regular inspections of the cutter head during subsequent use to ensure that the cutter head does not exceed its service life.

[0026] Second implementation method: Figure 2-7 As shown, the detection end of the tool detector 2 is installed with an image collector and a detection probe, data receivers 3 matching the tool detector 2 are installed on both sides of the upper end of the main bracket 11, a docking telescopic rod 4 is installed on the data receiver 3, the docking telescopic rod 4 includes an electric push rod connected to the data receiver 3, a docking socket is provided at the top of the tool detector 2, and a docking plug matching the docking socket is installed at the movable end of the docking telescopic rod 4.

[0027] The tool detector 2 includes a housing 21 , and one end of the housing 21 close to the tool installation shaft 15 is rotatably connected to a detection arm 22 . The detection arm 22 rotates and extends toward the tool head installed at the tool installation shaft 15 .

[0028] The detection arm 22 includes a rotating arm 221, which is rotatably connected to the shell 21 through a hollow rotating shaft 222. A stepper motor for driving the hollow rotating shaft 222 to rotate is installed on the shell 21. A movable arm 223 is plugged into the rotating arm 221, and a corrugated air pipe 224 connected to the hollow rotating shaft 222 is installed on the movable arm 223. An inflation interface communicating with the hollow rotating shaft 222 is installed at the top of the shell 21, and an inflation joint is installed at the movable end of the docking telescopic rod 4.

[0029] The image collector includes a high-definition camera and an infrared image acquisition device, and the detection probe includes a temperature detection probe, which is used to collect multi-point temperature distribution data on the tool head. The image collector and the detection probe are respectively arranged on the top of the detection arms 22 of the two tool detectors 2; a flexible data cable is passed through the detection arm 22, and the flexible data cable passes through the hollow rotating shaft 222 and is connected to the docking socket.

[0030] The detection arm 22 of the tool detector 2 in this embodiment can adjust the tilt angle through a stepper motor when working. By inflating the corrugated air tube 224, the corrugated air tube 224 expands and then pushes the movable arm 223 to move, so as to adjust the length of the detection arm 22. When the tool detector 2 performs detection work, the image collector or detection probe on the detection arm 22 can be attached to the tool head to be detected, so as to obtain accurate temperature distribution data and image data.

[0031] In summary, this solution monitors and analyzes the working status of the tool in real time, evaluates the remaining service life of the tool based on the tool usage and monitoring data, sets more accurate detection nodes and alarm nodes for subsequent tool use, and regularly performs automatic detection to update the service life assessment, thereby ensuring that the tool does not exceed its optimal service life during use and avoiding production accidents and economic losses caused by excessive tool wear.

[0032] In summary, this solution achieves accurate prediction and effective management of the tool life of five-axis machine tools through intelligent monitoring and management, providing strong technical support for improving machine tool processing efficiency and tool utilization efficiency.

[0033] In view of current practical needs, the above-mentioned implementation mode adopted in this application is not limited to the scope of protection. Various changes made within the knowledge scope of technical personnel in this field without departing from the concept of this application still fall within the scope of protection of the present invention.

Claims

1. An intelligent five-axis machine tool tool life prediction and management system, comprising a system end and a device end; the device end comprises a tool mounting frame (1) mounted on the machine tool, a tool head and a tool detector (2) being mounted on the tool mounting frame (1), characterized in that: The system end includes a processor, and the processor is connected to a monitoring module, a detection module, a prediction module and a control module; The monitoring module is used to collect monitoring data of the tool head on the tool mounting frame (1) when it is working, the monitoring data including the number of times the tool is used, the use time, the working temperature, the vibration data during operation and the cutting force data during operation; The detection module is used to evaluate the wear condition of the tool head according to the detection result of the tool detector (2); The prediction module estimates the remaining service life of the tool based on the monitoring data and the detection results of the detection module. The control module is used to control the operation of the machine tool and the tool detector (2); The tool mounting frame (1) is provided with a temperature sensor, a vibration sensor and a cutting force sensor matching the tool; The tool mounting frame (1) comprises a main bracket (11), the lower end of the main bracket (11) is rotatably connected to a rotating disk (12), the rotating disk (12) is fixedly connected to a mounting platform (13), the upper and lower ends of the mounting platform (13) are respectively mounted with a motor (14) and a tool mounting shaft (15), and the power output end of the motor (14) is fixedly connected to the tool mounting shaft (15); the upper end of the main bracket (11) is mounted with a servo motor (16), and a transmission belt is connected between the power output end of the servo motor (16) and the rotating disk (12); The tool detectors (2) are arranged in pairs at the side ends of the mounting platform (13); self-resetting slide rails (5) matching the tool detectors (2) are installed at both ends of the mounting platform (13); an image collector and a detection probe are installed at the detection end of the tool detector (2); data receivers (3) matching the tool detectors (2) are installed on both sides of the upper end of the main bracket (11); a docking telescopic rod (4) is installed on the data receiver (3); a docking socket is provided at the top end of the tool detector (2); and a docking plug matching the docking socket is installed at the movable end of the docking telescopic rod (4).

2. The intelligent five-axis machine tool tool life prediction and management system according to claim 1, characterized in that: The tool detector (2) comprises a housing (21); one end of the housing (21) close to the tool mounting shaft (15) is rotatably connected to a detection arm (22); the detection arm (22) rotates and extends toward a tool head mounted on the tool mounting shaft (15).

3. The intelligent five-axis machine tool tool life prediction and management system according to claim 2, characterized in that: The detection arm (22) comprises a rotating arm (221), the rotating arm (221) being rotatably connected to the housing (21) via a hollow rotating shaft (222), a stepping motor for driving the hollow rotating shaft (222) to rotate being mounted on the housing (21), a movable arm (223) being plugged into the rotating arm (221), a corrugated air pipe (224) connected to the hollow rotating shaft (222) being mounted on the movable arm (223), an inflation interface communicating with the hollow rotating shaft (222) being mounted at the top end of the housing (21), and an inflation joint being mounted at the movable end of the docking telescopic rod (4).

4. The intelligent five-axis machine tool tool life prediction and management system according to claim 1, characterized in that: The self-resetting slide rail (5) comprises a slide rail mounted on a mounting platform (13), a slide table being slidably connected to the slide rail, the housing (21) being fixedly connected to the slide table, and a compression spring being connected between the slide table and the bottom end of the slide rail.

5. The intelligent five-axis machine tool tool life prediction and management system according to claim 1, characterized in that: A laser receiver is installed at the bottom end of the motor (14), and a laser transmitter matching the laser receiver is installed at the bottom end of the servo motor (16).

6. The intelligent five-axis machine tool tool life prediction and management system according to claim 1, characterized in that: Before the tool detector (2) performs detection work, the servo motor (16) drives the mounting platform (13) to reset so that the tool mounting shaft (15) is vertically facing the ground, and then controls the tool detector (2) to dock with the docking telescopic rod (4) so ​​that the tool detector (2) is pushed to the side end of the tool head, and then controls the stepper motor to work so that the detection arm (22) rotates until the detection probe and the image collector at the top of the detection arm (22) are close to the tool head.

7. The intelligent five-axis machine tool tool life prediction and management system according to claim 1, characterized in that: The image collector comprises a high-definition camera and an infrared image collection device, the detection probe comprises a temperature detection probe, and the image collector and the detection probe are respectively arranged on two tool detectors (2).

8. The intelligent five-axis machine tool tool life prediction and management system according to claim 1, characterized in that: The prediction module sets a detection node or an alarm node according to the remaining service life; the detection nodes are evenly set within the remaining service life of the tool, and the alarm node is set to a set time interval from the end of the remaining service life of the tool head; When the cutter head works to the detection node and the alarm node, the cutter detector (2) performs detection work on the cutter head.

9. The intelligent five-axis machine tool tool life prediction and management system according to claim 1, characterized in that: The processor is connected to an alarm module. When the monitoring module detects that the remaining service life of the cutter head is less than a set value and the monitoring data is not within the set value range, the monitoring module sends a signal to the alarm module and the control module. The alarm module performs an audible and visual alarm and sends an alarm message, and the control module controls the machine tool to shut down.

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