New energy heavy truck stamping die wear monitoring system and method

Abstract

The invention relates to the technical field of die monitoring, and discloses a new energy heavy truck stamping die wear monitoring system and method.The new energy heavy truck stamping die wear monitoring system comprises a monitoring unit and a control unit, and the monitoring unit comprises a multi-channel acoustic emission monitoring module, an ultrasonic monitoring module, a spectrum confocal monitoring module, a temperature monitoring module, a pressure monitoring module and a data acquisition module; the data acquisition module is used for acquiring monitored data signals, and the control unit is used for controlling the monitoring unit and displaying a monitoring result. The effect of monitoring the abrasion condition of the stamping die in real time can be achieved, the situation that mass produced parts do not reach the standard is avoided, the acoustic emission sensor is installed on the stamping die to monitor acoustic signals of the stamping die in the using process in real time, and therefore the abrasion condition of the stamping die is judged; the wear condition is monitored by measuring sound wave reflection inside or on the surface of the stamping die through the arranged ultrasonic sensor, and tiny changes on the surface of the stamping die can be detected.

Description

Technical Field

[0001] The present invention belongs to the technical field of mold monitoring, and in particular, relates to a system and method for monitoring the wear of a stamping mold for a new energy heavy truck. Background Art

[0002] Stamping dies are special process equipment used to process materials (metal or non-metal) into parts (or semi-finished products) during cold stamping. They are called cold stamping dies (commonly known as cold stamping dies). Stamping is a pressure processing method that uses a die installed on a press to apply pressure to the material at room temperature to separate or plastically deform it, thereby obtaining the desired parts.

[0003] In the production and processing of new energy heavy-duty truck parts, some parts need to be processed using stamping dies. The stamping dies need to be in high-frequency contact with the workpiece during operation, and each set of stamping dies needs to produce up to thousands of workpieces. Therefore, the wear of the stamping dies is very serious. The wear of the stamping dies needs to be monitored in real time during the production process. Otherwise, not only will a large number of production parts fail to meet the standards, but the machine will also be shut down due to the failure to prepare the stamping dies, resulting in huge economic losses.

[0004] In view of this, the present invention is proposed. Summary of the invention

[0005] In order to solve the problem that each set of stamping dies needs to produce up to thousands of workpieces, the stamping dies are severely worn. In the production process, it is necessary to monitor the wear of the stamping dies in real time. Otherwise, not only will a large number of production parts fail to meet the standards, but also the machine will stop due to the unprepared stamping dies, thereby causing huge economic losses. The basic concept of the technical solution adopted by the present invention is:

[0006] A new energy heavy-duty truck stamping die wear monitoring system comprises a monitoring unit and a control unit, wherein the monitoring unit comprises a multi-channel acoustic emission monitoring module, an ultrasonic monitoring module, a spectral confocal monitoring module, a temperature monitoring module, a pressure monitoring module and a data acquisition module, wherein the data acquisition module is used to collect monitoring data signals, and the control unit is used to control the monitoring unit and display monitoring results, wherein the control unit comprises an electrical signal connection processing module, a parameter adjustment module and a terminal display module, wherein the electrical signal connection processing module is used to receive monitoring information and process it, wherein the parameter adjustment module and the terminal display module are both electrically connected to the electrical signal connection processing module, wherein the parameter adjustment module is used to adjust stamping parameters, and wherein the terminal display module is used to display monitoring results.

[0007] As a preferred embodiment of the present invention, the multi-channel acoustic emission monitoring module includes an acoustic emission sensor. The acoustic emission sensor is installed on the stamping die to monitor the sound signal of the stamping die in real time during use, thereby judging the wear condition of the stamping die.

[0008] As a preferred embodiment of the present invention, the ultrasonic monitoring module includes an ultrasonic sensor, which monitors the wear condition by measuring the sound wave reflection inside or on the surface of the stamping die through the ultrasonic sensor, and can detect slight changes on the surface of the stamping die.

[0009] As a preferred embodiment of the present invention, the spectral confocal monitoring module includes a spectral confocal sensor, which uses the principle that different wavelengths of light have different focal lengths in the lens system to measure the position change of the stamping die surface and evaluate the wear condition by detecting the change in the dispersion degree of the reflected light.

[0010] As a preferred embodiment of the present invention, the temperature monitoring module includes a temperature sensor, which measures the temperature change of the stamping die during operation. Abnormal temperature increase indicates excessive wear or failure of the stamping die.

[0011] As a preferred embodiment of the present invention, the pressure monitoring module includes a pressure sensor, which monitors the pressure change of the stamping die during the force-bearing process. If abnormal pressure is detected, it is a precursor to wear or damage of the stamping die.

[0012] A method for monitoring the wear of a stamping die for a new energy heavy truck comprises the following steps:

[0013] S1: Install the acoustic emission sensors: Install the acoustic emission sensors at least three positions on the stamping die in a non-collinear manner;

[0014] S2: Decomposition stamping stage: During stamping processing, each acoustic emission sensor collects non-stationary acoustic emission signals and transmits the signals to the data acquisition module. Each acoustic emission sensor forms an amplitude waveform that changes with time;

[0015] S3: Die wear monitoring and positioning: any amplitude waveform transmitted to the data acquisition module is subjected to time-frequency analysis through variational mode decomposition, and the amplitude waveform is decomposed into amplitude region waveforms that vary with time. Each amplitude region waveform corresponds to a stage of stamping processing, and then the amplitude region waveform corresponding to the slow pressing stage is taken to monitor and position the stamping die wear;

[0016] S4: Determine the degree of wear of the acoustic emission signal source: Based on the amplitude area waveform in the slow-down suppression stage, determine the degree of wear of the acoustic emission signal source:

[0017] If the acoustic emission signal source is not worn, execute S3 to continue monitoring the stamping die wear;

[0018] If the acoustic emission signal source is worn, the wear state of the acoustic emission signal source is judged according to S5.

[0019] S5: Acoustic emission signal source location: Determine the wear state of the wear point based on the amplitude area waveform in the slow-down suppression stage:

[0020] If the wear state of the wear point is normal wear, the spatial location of the acoustic emission signal source, i.e., the area on the stamping die with the most severe wear, i.e., the wear point, is obtained, and then S3 is executed;

[0021] If the state of the wear point is severe wear, the spatial location of the acoustic emission signal source, that is, the area on the mold with the most severe wear, that is, the wear point, is obtained, and the wear point is repaired or the mold is replaced according to actual needs, and then S3 is executed.

[0022] As a preferred embodiment of the present invention, in S1: an acoustic emission sensor is installed on the stamping die to monitor the sound signal of the stamping die in real time during use, so as to judge the wear condition of the stamping die.

[0023] As a preferred embodiment of the present invention, in S1:

[0024] After the acoustic emission sensor is installed, the ultrasonic sensor is installed. The ultrasonic sensor measures the reflection of sound waves inside or on the surface of the stamping die to monitor the wear condition. It can detect small changes on the surface of the stamping die, such as cracks and dents, and thus provide early warning.

[0025] After the ultrasonic sensor is installed, the spectral confocal sensor is installed. The spectral confocal sensor uses the principle that different wavelengths of light have different focal lengths in the lens system. By detecting the change in the dispersion degree of the reflected light, it measures the position change of the stamping die surface and evaluates the wear condition.

[0026] As a preferred embodiment of the present invention, in S1:

[0027] After the spectral confocal sensor is installed, the temperature sensor is installed. The temperature change of the stamping die during operation is measured by the temperature sensor. Abnormal temperature rise indicates excessive wear or failure of the stamping die, which helps to find problems with the stamping die in time.

[0028] After the temperature sensor is installed, the pressure sensor is installed. The pressure sensor is used to monitor the pressure changes of the stamping die during the stress process. If abnormal pressure is detected, it is a precursor to wear or damage of the stamping die. This helps to fully understand the stress conditions of the stamping die and prevent potential problems.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] In the present invention, an acoustic emission sensor is installed on the stamping die to monitor the sound signal of the stamping die in real time during use, so as to judge the wear condition of the stamping die; an ultrasonic sensor is set to measure the sound wave reflection inside or on the surface of the stamping die to monitor the wear condition, and it is possible to detect slight changes on the surface of the stamping die; a spectral confocal sensor is set, and the principle of different focal lengths of light of different wavelengths in a lens system is utilized to measure the position change of the surface of the stamping die by detecting the change in the dispersion degree of the reflected light to evaluate the wear condition; a temperature sensor is used to measure the temperature change of the stamping die during operation, and an abnormal temperature increase indicates excessive wear or failure of the stamping die, which helps to discover problems with the stamping die in time; a pressure sensor is used to monitor the pressure change of the stamping die during the stress process, and if abnormal pressure is monitored, it is a precursor to wear or damage of the stamping die, which helps to fully understand the stress condition of the stamping die and prevent potential problems, thereby achieving the effect of real-time monitoring of the wear condition of the stamping die, avoiding the situation where large quantities of produced parts do not meet the standards, and ensuring production quality.

[0031] The specific implementation modes of the present invention are further described in detail below in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In the attached picture:

[0033] Figure 1 This is a structural block diagram of a new energy heavy truck stamping die wear monitoring system of the present invention;

[0034] Figure 2 The present invention is a flow chart of a method for monitoring wear of a stamping die for a new energy heavy truck. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. The following embodiments are used to illustrate the present invention.

[0036] like Figure 1 to Figure 2 Shown

[0037] A new energy heavy-duty truck stamping die wear monitoring system comprises a monitoring unit and a control unit. The monitoring unit comprises a multi-channel acoustic emission monitoring module, an ultrasonic monitoring module, a spectral confocal monitoring module, a temperature monitoring module, a pressure monitoring module and a data acquisition module. The data acquisition module is used to collect monitoring data signals. The control unit is used to control the monitoring unit and display monitoring results. The control unit comprises an electrical signal connection processing module, a parameter adjustment module and a terminal display module. The electrical signal connection processing module is used to receive and process monitoring information. The parameter adjustment module and the terminal display module are both electrically connected to the electrical signal connection processing module. The parameter adjustment module is used to adjust stamping parameters. The terminal display module is used to display monitoring results.

[0038] The multi-channel acoustic emission monitoring module includes an acoustic emission sensor, which is installed on the stamping die to monitor the sound signal of the stamping die in real time during use, so as to judge the wear condition of the stamping die;

[0039] The ultrasonic monitoring module includes an ultrasonic sensor, which monitors the wear by measuring the reflection of sound waves inside or on the surface of the stamping die. It can detect small changes on the surface of the stamping die;

[0040] The spectral confocal monitoring module includes a spectral confocal sensor, which uses the principle that different wavelengths of light have different focal lengths in the lens system to measure the position change of the stamping die surface by detecting the change in the dispersion degree of the reflected light and evaluate the wear condition. This method has the characteristics of high precision (up to micron level), non-contact and real-time.

[0041] The temperature monitoring module includes a temperature sensor, which measures the temperature change of the stamping die during operation. Abnormal temperature rise indicates excessive wear or failure of the stamping die.

[0042] The pressure monitoring module includes a pressure sensor, which monitors the pressure changes of the stamping die during the force-bearing process. If abnormal pressure is detected, it is a precursor to wear or damage of the stamping die.

[0043] A method for monitoring the wear of a stamping die for a new energy heavy truck comprises the following steps:

[0044] S1: Install the acoustic emission sensors: Install the acoustic emission sensors at least three positions on the stamping die in a non-collinear manner;

[0045] S2: Decomposition stamping stage: During stamping processing, each acoustic emission sensor collects non-stationary acoustic emission signals and transmits the signals to the data acquisition module. Each acoustic emission sensor forms an amplitude waveform that changes with time;

[0046] S3: Die wear monitoring and positioning: any amplitude waveform transmitted to the data acquisition module is subjected to time-frequency analysis through variational mode decomposition, and the amplitude waveform is decomposed into amplitude region waveforms that vary with time. Each amplitude region waveform corresponds to a stage of stamping processing, and then the amplitude region waveform corresponding to the slow pressing stage is taken to monitor and position the stamping die wear;

[0047] S4: Determine the degree of wear of the acoustic emission signal source: Based on the amplitude area waveform in the slow reduction stage, determine the degree of wear of the acoustic emission signal source:

[0048] If the acoustic emission signal source is not worn, execute S3 to continue monitoring the stamping die wear;

[0049] If the acoustic emission signal source is worn, the wear state of the acoustic emission signal source is judged according to S5.

[0050] S5: Acoustic emission signal source location: Determine the wear state of the wear point based on the amplitude area waveform in the slow-down suppression stage:

[0051] If the wear state of the wear point is normal wear, the spatial location of the acoustic emission signal source, i.e., the area on the stamping die with the most severe wear, i.e., the wear point, is obtained, and then S3 is executed;

[0052] If the state of the wear point is severe wear, the spatial location of the acoustic emission signal source, that is, the area on the mold with the most severe wear, that is, the wear point, is obtained, and the wear point is repaired or the mold is replaced according to actual needs, and then S3 is executed.

[0053] In S1:

[0054] By installing an acoustic emission sensor on the stamping die, the sound signal of the stamping die during use can be monitored in real time to determine the wear condition of the stamping die.

[0055] After the acoustic emission sensor is installed, the ultrasonic sensor is installed. The ultrasonic sensor measures the reflection of sound waves inside or on the surface of the stamping die to monitor the wear condition. It can detect small changes on the surface of the stamping die, such as cracks and dents, and thus provide early warning.

[0056] After the ultrasonic sensor is installed, the spectral confocal sensor is installed. The spectral confocal sensor uses the principle that different wavelengths of light have different focal lengths in the lens system. By detecting the change in the dispersion degree of the reflected light, it measures the position change of the stamping die surface and evaluates the wear condition.

[0057] After the spectral confocal sensor is installed, the temperature sensor is installed. The temperature change of the stamping die during operation is measured by the temperature sensor. Abnormal temperature rise indicates excessive wear or failure of the stamping die, which helps to find problems with the stamping die in time.

[0058] After the temperature sensor is installed, the pressure sensor is installed. The pressure sensor is used to monitor the pressure changes of the stamping die during the stress process. If abnormal pressure is detected, it is a precursor to wear or damage of the stamping die. This helps to fully understand the stress conditions of the stamping die and prevent potential problems.

Claims

1. A new energy heavy truck stamping die wear monitoring system, including a monitoring unit and a control unit, characterized in that: The monitoring unit includes a multi-channel acoustic emission monitoring module, an ultrasonic monitoring module, a spectral confocal monitoring module, a temperature monitoring module, a pressure monitoring module and a data acquisition module. The data acquisition module is used to collect the monitoring data signal. The control unit is used to control the monitoring unit and display the monitoring results. The control unit includes an electrical signal connection processing module, a parameter adjustment module and a terminal display module. The electrical signal connection processing module is used to receive and process the monitoring information. The parameter adjustment module and the terminal display module are both electrically connected to the electrical signal connection processing module. The parameter adjustment module is used to adjust the stamping parameters. The terminal display module is used to display the monitoring results.

2. According to claim 1, a new energy heavy truck stamping die wear monitoring system is characterized in that: The multi-channel acoustic emission monitoring module includes an acoustic emission sensor. The acoustic emission sensor is installed on the stamping die to monitor the sound signal of the stamping die in real time during use, thereby judging the wear condition of the stamping die.

3. The new energy heavy truck stamping die wear monitoring system according to claim 1 is characterized in that: The ultrasonic monitoring module includes an ultrasonic sensor, which monitors the wear condition by measuring the sound wave reflection inside or on the surface of the stamping die through the ultrasonic sensor, and can detect slight changes on the surface of the stamping die.

4. The new energy heavy truck stamping die wear monitoring system according to claim 1 is characterized in that: The spectral confocal monitoring module includes a spectral confocal sensor, which uses the principle that different wavelengths of light have different focal lengths in a lens system to measure the position change of the stamping die surface and evaluate the wear condition by detecting the change in the dispersion degree of reflected light.

5. The new energy heavy truck stamping die wear monitoring system according to claim 1 is characterized in that: The temperature monitoring module includes a temperature sensor, which measures the temperature change of the stamping die during operation. Abnormal temperature increase indicates excessive wear or failure of the stamping die.

6. The new energy heavy truck stamping die wear monitoring system according to claim 1 is characterized in that: The pressure monitoring module includes a pressure sensor, which monitors the pressure change of the stamping die during the force-bearing process. If abnormal pressure is detected, it is a precursor to wear or damage of the stamping die.

7. A method for monitoring the wear of stamping dies for new energy heavy trucks, characterized in that: A new energy heavy truck stamping die wear monitoring system applied to any one of claims 1 to 6 comprises the following steps: S1: Install the acoustic emission sensors: Install the acoustic emission sensors at least three positions on the stamping die in a non-collinear manner; S2: Decomposition stamping stage: During stamping processing, each acoustic emission sensor collects non-stationary acoustic emission signals and transmits the signals to the data acquisition module. Each acoustic emission sensor forms an amplitude waveform that changes with time; S3: Die wear monitoring and positioning: any amplitude waveform transmitted to the data acquisition module is subjected to time-frequency analysis through variational mode decomposition, and the amplitude waveform is decomposed into amplitude region waveforms that vary with time. Each amplitude region waveform corresponds to a stage of stamping processing, and then the amplitude region waveform corresponding to the slow pressing stage is taken to monitor and position the stamping die wear; S4: Determine the degree of wear of the acoustic emission signal source: Based on the amplitude area waveform in the slow reduction stage, determine the degree of wear of the acoustic emission signal source: If the acoustic emission signal source is not worn, execute S3 to continue monitoring the stamping die wear; If the acoustic emission signal source is worn, the wear state of the acoustic emission signal source is judged according to S5. S5: Acoustic emission signal source location: Determine the wear state of the wear point based on the amplitude area waveform in the slow-down suppression stage: If the wear state of the wear point is normal wear, the spatial location of the acoustic emission signal source, i.e., the area on the stamping die with the most severe wear, i.e., the wear point, is obtained, and then S3 is executed; If the state of the wear point is severe wear, the spatial location of the acoustic emission signal source, that is, the area on the mold with the most severe wear, that is, the wear point, is obtained, and the wear point is repaired or the mold is replaced according to actual needs, and then S3 is executed.

8. The method for monitoring the wear of stamping dies for new energy heavy trucks according to claim 7 is characterized in that: In S1: an acoustic emission sensor is installed on the stamping die to monitor the sound signal of the stamping die in real time during use, so as to judge the wear condition of the stamping die.

9. The method for monitoring the wear of stamping dies for new energy heavy trucks according to claim 7 is characterized in that: In said S1: After the acoustic emission sensor is installed, the ultrasonic sensor is installed. The ultrasonic sensor measures the reflection of sound waves inside or on the surface of the stamping die to monitor the wear condition. It can detect small changes on the surface of the stamping die, such as cracks and dents, and thus provide early warning. After the ultrasonic sensor is installed, the spectral confocal sensor is installed. The spectral confocal sensor uses the principle that different wavelengths of light have different focal lengths in the lens system. By detecting the change in the dispersion degree of the reflected light, it measures the position change of the stamping die surface and evaluates the wear condition.

10. The method for monitoring the wear of stamping dies for new energy heavy trucks according to claim 7 is characterized in that: In said S1: After the spectral confocal sensor is installed, the temperature sensor is installed. The temperature change of the stamping die during operation is measured by the temperature sensor. Abnormal temperature rise indicates excessive wear or failure of the stamping die, which helps to find problems with the stamping die in time. After the temperature sensor is installed, the pressure sensor is installed. The pressure sensor is used to monitor the pressure changes of the stamping die during the stress process. If abnormal pressure is detected, it is a precursor to wear or damage of the stamping die. This helps to fully understand the stress conditions of the stamping die and prevent potential problems.

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