Part size quality control system and method

Abstract

The invention discloses a part dimension quality control system and method, and the system comprises a control unit, a detection module, a data analysis module, a data storage unit, a terminal display module and an alarm module, and the detection module, the terminal display module and the alarm module are connected with the control unit. The data analysis module and the data storage unit are respectively connected with the detection module, the detection module is used for carrying out real-time detection on the produced mechanical parts to obtain detection data of the mechanical parts, and the data analysis module is used for carrying out quality control analysis on the detection data of the mechanical parts. Determining a corresponding detection result according to the detection data of each mechanical part, wherein the detection result comprises whether the detection is qualified or not and corresponding detailed result data; if the detection is not qualified; under the condition of off-line small sample size measurement of mechanical parts, the assembly size quality information can be timely and effectively extracted, and accurate evaluation is carried out.

Description

Technical Field

[0001] The present invention relates to the technical field of component quality control, and more specifically, to a component dimension quality control system and method. Background Art

[0002] Mechanical parts, also known as mechanical elements, are the basic elements of machinery and an important part of automobile parts. They are inseparable individual parts that make up machinery and machines. The control and improvement of their quality requires an accurate and efficient quality control system and method. For automobile parts, the dimensional accuracy of assembly is the main assembly quality requirement. At present, the major domestic automobile parts manufacturers do not have a system and method for dimensional quality control. Although the dimensional measurement of parts has been carried out by equipment such as three-coordinate measuring machines, there are still disadvantages such as single quality inspection devices, backward control methods, unreasonable control systems, and low work efficiency. The automobile parts manufacturing process is a large-scale batch production process. At present, most parts manufacturing companies cannot achieve 100% detection, and the evaluation of dimensional quality can only be carried out by offline small sample sampling. Therefore, it is of great practical significance to accurately evaluate the dimensional quality of automobile parts assembly through standardized sampling and analysis of measurement data, and to explore useful measurement data for process analysis based on the 2mm engineering requirements of dimensional quality control and the goal of "data-driven quality". Summary of the invention

[0003] 1. Technical issues to be resolved

[0004] In view of the problems existing in the prior art, the present invention provides a component dimension quality control system and method to solve the technical problems mentioned in the background technology.

[0005] (II) Technical solution

[0006] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a component size quality control system, comprising a control unit, a detection module, a data analysis module, a data storage unit, a terminal display module and an alarm module, wherein the detection module, the terminal display module and the alarm module are respectively connected to the control unit, and the data analysis module and the data storage unit are respectively connected to the detection module, wherein the detection module is used to perform real-time detection on the produced mechanical components and obtain the detection data of each mechanical component, wherein the data analysis module is used to perform quality control analysis on the detection data of the mechanical components, and determine the corresponding detection result according to the detection data of each mechanical component, wherein the detection result includes whether the detection is qualified and the corresponding detailed result data; if the detection is unqualified, the detailed result data includes the unqualified position and the deviation value; if the detection is qualified, the detailed result data includes the error position and the error value, wherein the alarm module is used to issue reminders to unqualified mechanical components so that the staff can quickly take away the unqualified components, wherein the terminal display module is used to display data information so that the staff can better record and grasp the data, and wherein the data storage module is used to store the data for later viewing.

[0007] The present invention is further configured such that the control unit adopts a PLC controller to control each module and program it in advance.

[0008] The present invention is further configured such that the working method of the detection module includes: establishing a technology library, storing various verified gear size detection technologies in the technology library, marked as backup technologies; and setting corresponding technical description data for each backup technology; identifying the detection environment input by the user, and determining the corresponding backup technology as the recommended technology based on the obtained detection environment and the technical description data; recommending the recommended technology to the user, and the user determining the applied detection technology; and performing detection based on the applied detection technology.

[0009] The present invention is further configured such that the method for determining the recommended technology includes: inputting the obtained detection environment into the technology library for matching, obtaining various alternative technologies that meet the detection environment requirements, and marking them as candidate technologies; identifying the detection performance value and cost corresponding to the candidate technologies, and marking the detection performance value and the cost as HZ and CBM respectively; calculating the corresponding recommended value TF according to the recommended formula TF=b3×HZ-b4×CBM1.38, where b3 and b4 are both proportional coefficients, and the value range is 0<b3<1, 0<b4<1; marking the candidate technology with the highest recommended value as the recommended technology.

[0010] The present invention also includes a component size quality control method, comprising the following steps:

[0011] Step 1: Establish a technology library, identify the test environment input by the user, and determine the corresponding recommended technology based on the test environment and technical specification data obtained; Measurement data sampling: The dimensional data of the parts is measured and collected through the line-side inspection fixture and the three-dimensional coordinate measuring machine, and the measured data results are sent to the central computer for storage and processing;

[0012] Recommending the recommended technology to the user, and allowing the user to determine the applied detection technology; performing detection according to the applied detection technology;

[0013] Determine the corresponding detection result according to the detection data of each gear, and set the detection curve graph corresponding to each statistical part according to the obtained detection result;

[0014] Step 2: judging whether gear production needs gear production quality control based on each detection curve graph;

[0015] When it is determined that gear production quality control is necessary, the reasons for exceeding the standard are determined; an early warning is issued to the corresponding management personnel, and the reasons for exceeding the standard are sent to the corresponding management personnel; the management personnel conduct verification and gear production adjustments based on the reasons for exceeding the standard, and analyze the measurement data: the lineside inspection fixture measurement data and the three-coordinate measuring machine measurement data are processed separately; for the lineside inspection fixture measurement data, the mean-range chart analysis is used to obtain the mean-range control chart.

[0016] The present invention is further configured such that, for the measurement data of the three-coordinate measuring machine, the following steps are adopted: using the exponentially weighted moving average method to perform error separation calculations to obtain trend data and fluctuation data; obtaining a trend analysis chart based on the trend data; performing fluctuation quality evaluation based on the fluctuation data; and applying the fluctuation data after data separation to obtain stage 6σ values ​​and dimensional process capability evaluation.

[0017] The present invention is further configured such that the above steps also include principal component analysis: providing the main pattern of changes in a set of component analysis data; correlation analysis: analyzing and calculating the degree of similarity between trends in the measurement data of the measuring points, and analyzing the correlation between dimensions in different areas of the parts; cause determination: combining data analysis with a process knowledge model to determine the cause; improvement measures: proposing short-term measures and long-term measures based on the determined causes and tracking their implementation, and timely updating the tracking status until the defects are suppressed and the problems are solved.

[0018] The present invention is further configured that the measurement data analysis analyzes the data obtained by the lineside inspection fixture through a mean-range chart to judge whether the measurement result is within the upper and lower control limits, and immediately alarms if it exceeds the control line; the data obtained by the offline three-coordinate measuring machine is processed by an exponentially weighted moving average method, and when screening the processed data, if one of the following situations is found:

[0019] (1) The measured value exceeds the design tolerance;

[0020] (2) The 6σ of the measured value exceeds 2 times the design tolerance;

[0021] (3) The most recent 10 measurement records are all greater than or less than the sample mean;

[0022] Then an immediate alarm is issued.

[0023] The present invention is further configured such that when the exponentially weighted moving average method is used to perform error separation on the detection data, an average value is calculated for a new set of data each day, and trend data in the data is obtained by recursive operation. The number S of historical data introduced is taken as 3-5, and the weighting coefficient W is taken as 0.2-0.5. High-frequency fluctuation data is obtained by taking the difference between the original data and the trend data.

[0024] (III) Beneficial effects

[0025] Compared with the prior art, the present invention provides a component dimension quality control system and method, which has the following beneficial effects:

[0026] The present invention can timely and effectively extract assembly dimension quality information and make accurate evaluation under the condition of off-line small sample dimension measurement of mechanical parts. The evaluation index given can evaluate the dimension quality and dimension process capability of parts. Through evaluation and analysis, a basis can be provided for the assessment of the tooling status level of the parts production line in the trial production stage. Due to the timely and accurate feedback, the dimension quality problem solving cycle can be effectively shortened and the delivery speed of new parts can be accelerated. In addition, during the normal production period, the production line status can be effectively monitored, problems can be found and solved in time, and the dynamic control of gear quality based on real-time detection data can be realized through the mutual cooperation between the detection module and the data analysis module, so as to improve the analysis efficiency, so that when there are production quality problems, the user can be warned in time, the production quality can be guaranteed and the production loss can be reduced. By setting the detection module, the intelligent detection of each gear can be realized, and the appropriate detection technology can be intelligently recommended according to the actual detection environment of the user, so as to help the user improve the quality control system; at the same time, it is not limited to the specified detection technology, and the compatibility of the system is improved; it helps the user save costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is an overall system diagram of a component size quality control system in the present invention;

[0028] Figure 2 The figure is an overall flow chart of a component dimension quality control method in the present invention. DETAILED DESCRIPTION

[0029] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application may be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0030] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meanings as commonly understood by ordinary technicians in the technical field to which this application belongs.

[0031] In the present invention, unless otherwise specified, the directions used, such as "up" and "down", usually refer to the directions shown in the drawings, or to the vertical, perpendicular or gravity directions; similarly, for ease of understanding and description, "left" and "right" usually refer to the left and right shown in the drawings; "inside" and "outside" refer to the inside and outside relative to the outline of each component itself, but the above-mentioned directions are not used to limit the present invention.

[0032] See also Figure 1-2 A component size quality control system includes a control unit, a detection module, a data analysis module, a data storage unit, a terminal display module and an alarm module, wherein the detection module, the terminal display module and the alarm module are respectively connected to the control unit, and the data analysis module and the data storage unit are respectively connected to the detection module, wherein the detection module is used to perform real-time detection on the produced mechanical components and obtain the detection data of each mechanical component, wherein the data analysis module is used to perform quality control analysis on the detection data of the mechanical components, and determine the corresponding detection result according to the detection data of each mechanical component, wherein the detection result includes whether the detection is qualified and the corresponding detailed result data; if the detection is unqualified, the detailed result data includes the unqualified position and the deviation value; if the detection is qualified, the detailed result data includes the error position and the error value, wherein the alarm module is used to issue a reminder to the unqualified mechanical components so that the staff can quickly take away the unqualified components, wherein the terminal display module is used to display the data information so that the staff can better record and grasp the data, and wherein the data storage module is used to store the data for later viewing.

[0033] In a further embodiment, the control unit adopts a PLC controller to control each module and program it in advance; the working method of the detection module includes: establishing a technology library, storing various verified gear size detection technologies in the technology library, marked as backup technologies; and setting corresponding technical description data for each backup technology; identifying the detection environment input by the user, and determining the corresponding backup technology as a recommended technology based on the obtained detection environment and the technical description data; recommending the recommended technology to the user, and the user determines the applied detection technology; performing detection based on the applied detection technology; the determination method of the recommended technology includes: inputting the obtained detection environment into the technology library for matching, obtaining various alternative technologies that meet the detection environment requirements, and marking them as candidate technologies; identifying the detection performance value and cost corresponding to the candidate technology, and marking the detection performance value and the cost as HZ and CBM respectively; calculating the corresponding recommended value TF according to the recommended formula TF=b3×HZ-b4×CBM1.38, b3 and b4 are both proportional coefficients, and the value range is 0<b3<1, 0<b4<1; marking the candidate technology with the highest recommended value as the recommended technology.

[0034] The present invention also includes a component size quality control method, comprising the following steps:

[0035] Step 1: Establish a technology library, identify the test environment input by the user, and determine the corresponding recommended technology based on the test environment and technical specification data obtained; Measurement data sampling: The dimensional data of the parts is measured and collected through the line-side inspection fixture and the three-dimensional coordinate measuring machine, and the measured data results are sent to the central computer for storage and processing;

[0036] Recommending the recommended technology to the user, and allowing the user to determine the applied detection technology; performing detection according to the applied detection technology;

[0037] Determine the corresponding detection result according to the detection data of each gear, and set the detection curve graph corresponding to each statistical part according to the obtained detection result;

[0038] Step 2: judging whether gear production needs gear production quality control based on each detection curve graph;

[0039] When it is determined that gear production quality control is necessary, the reasons for exceeding the standard are determined; an early warning is issued to the corresponding management personnel, and the reasons for exceeding the standard are sent to the corresponding management personnel; the management personnel conduct verification and gear production adjustments based on the reasons for exceeding the standard, and analyze the measurement data: the lineside inspection fixture measurement data and the three-coordinate measuring machine measurement data are processed separately; for the lineside inspection fixture measurement data, the mean-range chart analysis is used to obtain the mean-range control chart.

[0040] In a further embodiment, the following steps are adopted for the measurement data of the three-coordinate measuring machine: using the exponential weighted moving average method to perform error separation calculation to obtain trend data and fluctuation data; obtaining a trend analysis chart based on the trend data; performing fluctuation quality evaluation based on the fluctuation data; applying the fluctuation data after data separation to obtain the stage 6σ value and dimensional process capability evaluation; the above steps also include principal component analysis: giving the main mode of changes in a set of component analysis data; correlation analysis: analyzing and calculating the similarity between the trends of the measurement data of the measuring points, and analyzing the correlation of the dimensions between different areas of the parts; cause determination: combining data analysis with the process knowledge model to determine the cause; improvement measures: proposing short-term measures and long-term measures based on the determined causes and tracking their implementation, and updating the tracking status in a timely manner until the defects are suppressed and the problems are solved;

[0041] The measurement data analysis described above uses a mean-range chart to analyze the data obtained by the lineside inspection fixture measurement to determine whether the measurement result is within the upper and lower control limits, and an immediate alarm is issued if it exceeds the control line; the data obtained by the offline three-coordinate measuring machine is processed by the exponential weighted moving average method. When screening the processed data, if one of the following situations is found:

[0042] (1) The measured value exceeds the design tolerance;

[0043] (2) The 6σ of the measured value exceeds 2 times the design tolerance;

[0044] (3) The most recent 10 measurement records are all greater than or less than the sample mean;

[0045] Then an immediate alarm is issued.

[0046] In a further embodiment, when the exponentially weighted moving average method is used to perform error separation on the detection data, the average value is calculated for a new set of data each day, and the trend data in the data is obtained by recursive operation. The number of historical data introduced S is taken as 3-5, and the weighting coefficient W is taken as 0.2-0.5. The high-frequency fluctuation data is obtained by taking the difference between the original data and the trend data.

[0047] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A component dimensional quality control system, characterized in that: It includes a control unit, a detection module, a data analysis module, a data storage unit, a terminal display module and an alarm module, wherein the detection module, the terminal display module and the alarm module are respectively connected to the control unit, and the data analysis module and the data storage unit are respectively connected to the detection module. The detection module is used to perform real-time detection on the produced mechanical parts and components to obtain the detection data of each mechanical part and component, and the data analysis module is used to perform quality control analysis on the detection data of the mechanical parts and components, and determine the corresponding detection results according to the detection data of each mechanical part and component, and the detection results include whether the detection is qualified and the corresponding detailed result data; if the detection is unqualified, the detailed result data includes the unqualified position and the deviation value; For qualified inspections, detailed result data include error location and error value. The alarm module is used to issue reminders for unqualified mechanical parts so that the staff can quickly remove the unqualified parts. The terminal display module is used to display data information so that the staff can better record and grasp the data. The data storage module is used to store the data for later viewing.

2. A component dimensional quality control system according to claim 1, characterized in that: The control unit adopts a PLC controller to control each module and program it in advance.

3. A component dimensional quality control system according to claim 2, characterized in that: The working method of the detection module includes: establishing a technology library, storing various verified gear size detection technologies in the technology library, marked as backup technologies; and setting corresponding technical description data for each backup technology; identifying the detection environment input by the user, and determining the corresponding backup technology as the recommended technology based on the obtained detection environment and the technical description data; recommending the recommended technology to the user, and the user determines the applied detection technology; and performing detection based on the applied detection technology.

4. A component dimensional quality control system according to claim 2, characterized in that: The method for determining the recommended technology includes: inputting the obtained detection environment into the technology library for matching, obtaining various alternative technologies that meet the detection environment requirements, and marking them as candidate technologies; identifying the detection performance value and cost corresponding to the candidate technology, and marking the detection performance value and the cost as HZ and CBM respectively; calculating the corresponding recommended value TF according to the recommended formula TF=b3×HZ-b4×CBM1.38, b3 and b4 are both proportional coefficients, and the value range is 0<b3<1, 0<b4<1; marking the candidate technology with the highest recommended value as the recommended technology.

5. The present invention also includes a method for controlling the quality of component dimensions, characterized in that: The following steps are involved: Step 1: Establish a technology library, identify the test environment input by the user, and determine the corresponding recommended technology based on the test environment and technical specification data obtained; Measurement data sampling: The dimensional data of the parts is measured and collected through the line-side inspection fixture and the three-dimensional coordinate measuring machine, and the measured data results are sent to the central computer for storage and processing; Recommending the recommended technology to the user, and allowing the user to determine the applied detection technology; performing detection according to the applied detection technology; Determine the corresponding detection result according to the detection data of each gear, and set the detection curve graph corresponding to each statistical part according to the obtained detection result; Step 2: judging whether gear production needs gear production quality control based on each detection curve graph; When it is determined that gear production quality control is necessary, the reasons for exceeding the standard are determined; an early warning is issued to the corresponding management personnel, and the reasons for exceeding the standard are sent to the corresponding management personnel; the management personnel conduct verification and gear production adjustments based on the reasons for exceeding the standard, and analyze the measurement data: the lineside inspection fixture measurement data and the three-coordinate measuring machine measurement data are processed separately; for the lineside inspection fixture measurement data, the mean-range chart analysis is used to obtain the mean-range control chart.

6. A component dimensional quality control method according to claim 5, characterized in that: The three-coordinate measuring machine measurement data adopts the following steps: using an exponentially weighted moving average method to perform error separation calculations to obtain trend data and fluctuation data; Obtain trend analysis chart based on trend data; perform fluctuation quality evaluation based on fluctuation data; The fluctuation data after application data separation is used to obtain the stage 6σ value and dimensional process capability evaluation.

7. A component dimensional quality control method according to claim 5, characterized in that: The above steps also include principal component analysis: giving the main pattern of changes in a set of component analysis data; correlation analysis: analyzing and calculating the similarity between the trends of the measurement data of the measuring points, and analyzing the correlation between the dimensions of different areas of the parts; cause determination: combining data analysis with the process knowledge model to determine the cause; improvement measures: proposing short-term and long-term measures based on the determined causes and tracking their implementation, and updating the tracking status in a timely manner until the defects are suppressed and the problems are solved.

8. A component dimensional quality control method according to claim 5, characterized in that: The measurement data analysis is to analyze the data obtained by the lineside inspection fixture measurement through the mean-range chart to judge whether the measurement result is within the upper and lower control limits, and to immediately alarm if it exceeds the control line; the data obtained by the offline three-dimensional coordinate measuring machine is processed by the exponential weighted moving average method, and when screening the processed data, if one of the following situations is found: (1) the measurement value exceeds the design tolerance; (2) the 6σ of the measurement value exceeds 2 times the design tolerance; (3) the most recent 10 measurement records are greater than or less than the sample mean; Then an immediate alarm is issued.

9. A component dimension quality control method according to claim 5, characterized in that: When the exponentially weighted moving average method is used to separate errors in the detection data, the average value is calculated for a new set of data each day, and the trend data in the data is obtained by recursive operation. The number of historical data introduced S is taken as 3-5, and the weighting coefficient W is taken as 0.2-0.

5. The high-frequency fluctuation data is obtained by taking the difference between the original data and the trend data.

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