Vortex profiling scanning control method based on G code

Abstract

The invention belongs to the technical field of nondestructive inspection, and particularly relates to an eddy current profiling scanning control method based on a G code. According to the eddy current profiling scanning control method, corresponding technological parameters used for conducting eddy current profiling scanning on irregular parts are compiled in a G code mode to form G code execution files, and the G code execution files corresponding to all models are independently arranged. Each G code execution file is analyzed by the PLC system to generate a corresponding PLC executable language, the corresponding PLC executable language is converted into a PLC executable command, and each servo system is controlled to operate through the PLC system, so that the eddy current probe performs profiling scanning along the surface of the workpiece; a command execution state and a command execution result are fed back to the configuration software, and a current path and an activation line are displayed; a closed loop is formed between the G code execution file and the corresponding servo system, and independent control is achieved; according to the invention, functions of complex multi-axis linkage, profiling scanning and the like can be realized so as to accurately execute eddy current detection.

Description

Technical Field

[0001] The invention belongs to the technical field of non-destructive flaw detection, and in particular relates to an eddy current profiling scanning control method based on G code. Background Art

[0002] Eddy current testing is a non-destructive testing technology that uses the principle of electromagnetic induction. When the detection coil is close to the conductive test piece being tested, eddy currents will be induced in the test piece. The size, distribution and flow form of the eddy currents will be affected by factors such as the conductivity, magnetic permeability, geometry and defects of the test piece. By analyzing the changes in the induced current in the detection coil, the performance and defects of the test piece can be inferred.

[0003] During the detection process, the size of the gap between the probe and the surface of the test piece directly affects the sensitivity and accuracy of the detection. In practical applications, it is necessary to adjust the gap between the probe and the surface of the test piece according to the specific detection requirements and the material properties of the test piece to ensure the best detection effect. Taking bearing eddy current flaw detection as an example, for conventional CRB bearings, the raceway is a straight line perpendicular to the end face, and a single-direction scan is sufficient to meet the fixed gap between the eddy current probe and the bearing raceway. For non-cylindrical bearings such as TRB and SRB, the raceway is an oblique line inclined at a certain angle or a more complex arc shape. In order to maintain a fixed distance between the probe and the raceway, multi-axis linkage is required to perform complex interpolation motion.

[0004] At present, the main solutions for automated equipment control systems in the field of bearing eddy current flaw detection are as follows: 1. Use a dedicated CNC system, which is provided by foreign manufacturers such as Siemens, FANUC, etc., and domestic manufacturers such as Guangzhou CNC, Huazhong CNC, etc., which has high cost, great difficulty in maintenance, and limited flexibility; 2. The control method of PLC+HMI+motion control card is adopted. It is necessary to program and configure PLC, motion control card and HMI separately, and ensure the normal communication between them. The system is highly complex and costly. 3.PLC+HMI: This control method has limitations, the operation and programming are relatively complex, and the scalability is poor.

[0005] In the field of bearing eddy current flaw detection, the above solutions all have some limitations in terms of cost and ease of use: high cost, poor reliability, closed technology, and poor flexibility.

[0006] In addition, according to the existing control method, the entire control process must form a closed loop in the PLC program. The PLC program must be compatible with all bearing models. Optimizing any command and parameter will affect the flaw detection of all models. The program is complicated and the flexibility is very poor (different bearing types require different numbers of areas to be distinguished. Some bearing rings have only 4 faces, which require the probe to be switched on and off 4 times. Some bearing rings have 14 faces, which require the probe to be switched on and off 14 times. The probe also needs to scan along different surfaces in turn). Every time a new model is introduced, all sizes and positions need to be divided into coordinates according to different areas and input into the system. The PLC controls the probe to move one coordinate at a time. This method is fine for cylindrical roller bearings, but for the tapered raceways and spherical raceways of tapered roller bearings and spherical roller bearings, interpolation motion needs to be done one coordinate at a time, which is very troublesome and prone to errors. Summary of the invention

[0007] The purpose of the present invention is to propose a G-code-based eddy current profiling scanning control method, introduce the flexible programming control method of the numerical control system into the PLC system, and adopt the combination of G-code and PLC system to realize eddy current profiling scanning of irregular parts, so that the detection is more flexible, and the formula establishment and management are simpler and more reliable.

[0008] The present invention adopts the following technical solutions to achieve the above-mentioned purpose: A G-code-based eddy current profiling scanning control method, the eddy current profiling scanning control method will be used for eddy current profiling scanning of irregular parts corresponding process parameters in the form of G code to form a G code execution file, and each model corresponding to the G code execution file is independently set, each of the G code execution files is parsed by a PLC system to generate a corresponding PLC executable language, converted into a PLC executable command, and the PLC system is used to control the operation of each servo system, so that the eddy current probe performs profiling scanning along the surface of the workpiece; and the state and result of the command execution are fed back to the configuration software to display the current path and the activation line; a closed loop is formed between the G code execution file and the corresponding servo system, and independent control is performed; the details are as follows: Step 1, generate G code execution file: draw or load workpiece drawings through CAD / CAM software on IPC, combine corresponding process parameters, determine the area to be scanned, scanning order, scanning speed, and generate G code execution file according to the confirmed scanning path; the G code execution file includes general commands and custom commands; the general commands include scanning starting point, end point, straight line, arc, rotation and delay, etc., and the custom commands include scanning start control, scanning shutdown control, probe opening, probe closing, eddy current detection parameter setting, etc.; the custom commands and the general commands are interspersed to form a complete scanning path; the G code execution file is stored in the folder specified by the IPC hard disk; the G code execution file is sent to the PLC system through the configuration software installed in the IPC, and stored in the storage medium of the PLC system to control the file interaction between the PLC and the IPC; Step 2: Display and edit G code execution files: The operator browses the files in the PLC system storage medium through the configuration software on the IPC, selects the corresponding G code execution file, and reads, edits, and saves it as needed; Step 3, G code file processing: The PLC system reads data from the selected G code execution file and transfers it line by line to the PLC data buffer area; the storage medium and the data buffer area can exchange data through the G code file processing module; Step 4. Program parser: (1) Check whether the syntax and semantics of the G code program written into the data buffer area conform to the rules; (2) The G code program written into the data buffer is translated through the language package set in the PLC system, and the G code is converted into the PLC executable language SCL; the language set in the PLC system includes general commands and custom commands, and the custom commands are commands defined according to the needs of eddy current detection; Step 5. Generate executable motion path: PLC reads the compiled PLC executable language SCL from the program parser, generates executable motion path, and sends it to the IPC configuration software for display, showing the current path and active line; Step 6: Convert into PLC executable commands: The PLC system executes the motion path and control commands, controls the probe through the horizontal, vertical and rotation axes to perform contour scanning along different surfaces of the ring, controls the eddy current flaw detection system to start detection before the start of the scan, starts the probe at the starting position of each scan area, collects eddy current data, closes the probe at the end position of each scan area, stops collecting eddy current data, closes the scan record at the end of the scan, and switches the detection parameters as needed during the scan.

[0009] The PLC system is equipped with a three-axis control process object, an absolute position feedback module, an incremental pulse feedback module, and an IO module. The three-axis control process object controls the servo drive system through an industrial switch, the absolute position feedback module collects absolute magnetic encoder signals in real time, the incremental pulse feedback module is connected to the electronic handwheel, and the IO module is connected to the input and output digital signals.

[0010] The servo system includes a servo driver, a servo motor, an absolute magnetic encoder, a synchronous belt, and a reducer. The servo system is the actuator of the entire system. The servo driver drives the servo motor to operate according to the PLC instructions, drives the motion mechanism to operate through the reducer or synchronous belt mechanism, and realizes precise position control through the feedback signal of the absolute magnetic encoder.

[0011] The present invention proposes a G-code-based eddy current profiling scanning control method, which adopts the IPC+PLC+servo architecture, combines the process programming advantages of the CAD / CAM software of the IPC platform, generates G-code according to the drawings of different models of workpieces and scanning requirements, displays and edits through the configuration software installed on the IPC, and compiles the G-code into PLC executable commands after the PLC system reads the G-code, simulating the functions of the numerical control system, and is used to accurately control the motion trajectory, speed and position accuracy of the probe scanning, and can realize complex multi-axis linkage, profiling scanning and other functions to accurately perform eddy current detection; at the same time, the G-code adds commands such as probe switch control and parameter setting control, which can accurately realize the different eddy current data collection requirements of each region. It can not only give play to the process programming advantages of the CAD / CAM software of the IPC platform, but also give play to the programming advantages of the G-code flow execution and the PLC instruction loop execution, the system is easy to expand and has high flexibility; the cost is low, and it is convenient for users to quickly realize various complex detection actions according to different product models, which can not only be applied to bearing eddy current flaw detection equipment, but also can be used in other occasions requiring complex motion control. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 Schematic diagram of the functional structure of the eddy current profiling scanning control method based on G code.

[0013] Figure 2 This is a schematic diagram of the functional interaction between the PLC system, servo system and main peripherals.

[0014] Figure 3 This is a control flow chart of the eddy current profiling scanning control method based on G code.

[0015] Figure 4 Flowchart for G-code parsing. DETAILED DESCRIPTION

[0016] A specific embodiment of the present invention is given in conjunction with the accompanying drawings, that is, in conjunction with the above technical solution, a completed control process is given mainly based on a certain command.

[0017] like Figure 1 As shown, a G-code-based eddy current profiling scanning control system running on a PLC system includes an IPC system, a touch screen module, a PLC system, an industrial switch, a servo system, an eddy current detection system, a display unit, etc. The IPC system is provided with a gigabit network port, an HDMI interface, etc.; the IPC system, the touch screen module, the PLC system, the servo system, the eddy current detection system, etc. are respectively connected to the industrial switch through the gigabit network port, and data exchange is achieved through the industrial switch; configuration software is installed in the IPC system; the IPC system is connected to the display unit through the HDMI interface; the eddy current detection system includes an eddy current detection probe, which is an integrated probe integrating three sensors.

[0018] like Figure 2 As shown, the PLC system is provided with a three-axis control process object, an absolute position feedback module, an incremental pulse feedback module, an IO module, etc.; the three-axis control process object controls the servo drive system through an industrial switch, including the movement of the three axes of the X-axis, the Z-axis, and the rotating axis, the X-axis controls the horizontal movement of the probe, the Z-axis controls the vertical movement of the probe, and the rotating axis controls the ±135° rotation of the probe; the servo system includes a servo motor, a servo driver, an absolute magnetic encoder, a synchronous belt, and a reducer, wherein the reducer is used for the control of the X-axis and the Z-axis, the synchronous belt is used for the control of the rotating axis, the servo system is the actuator of the entire system, and the servo driver The servo motor is driven to operate according to the PLC instruction, the motion mechanism is driven to operate through the reducer or synchronous belt mechanism, and the absolute magnetic encoder feedback signal is used to achieve precise position control; the absolute position feedback module collects the absolute magnetic encoder signal in real time and provides it to the PLC system for motion monitoring and closed-loop control; the incremental pulse feedback module is connected to the electronic handwheel, and manual adjustment of the mechanical motion is achieved by manually adjusting the electronic handwheel; the IO module is connected to input and output digital signals, and can be connected to various buttons, sound and light alarm lights and other peripherals. Various buttons are used for manual input control, and the sound and light alarm lights are used to output sound and light prompts for detection results and alarm signals.

[0019] Taking the eddy current detection of the outer ring of the bearing ring as an example, a G-code-based eddy current profiling scanning control method is proposed. The eddy current profiling scanning control method writes the corresponding process parameters for eddy current profiling scanning of the inner and outer rings of CRB, TRB, and SRB bearings in the form of G code to form a G code execution file, and the G code execution files corresponding to each bearing model are independently set. Each of the G code execution files is parsed by the PLC system to generate a corresponding PLC executable language, which is converted into a PLC executable command, and the PLC system is used to control the operation of each servo system so that the eddy current probe performs profiling scanning along the surface of the workpiece; and the status and results of the command execution are fed back to the configuration software to display the current path and activation line; a closed loop is formed between the G code execution file and the corresponding servo system, and independent control is performed; the details are as follows: Step 1, generate G code execution file: draw or load the workpiece drawing through the CAD software on the IPC, and generate the G code execution file according to the outer dimensions of the ring and the scanning path through the CAM module. The area to be scanned is the various surfaces of the ring, including the upper end face, outer diameter surface, raceway surface, lower end face, flange surface, etc.; edit the G code execution file, combine the corresponding process parameters, set the scanning speed and absolute position, add a custom command program on the basis of the original general command program, start the eddy current scanning record before the detection starts, call the eddy current detection parameters, and start when the probe reaches the upper end face. After the probe reaches the end position of the upper end surface, wait for the ferrule to rotate for one circle, and then turn on sensor 3. When the probe moves to the starting position of the outer diameter surface, turn on sensor 2. After the ferrule rotates for one circle, control the probe to move from the starting position to the scanning end position along the upper end surface, set the moving speed to match the ferrule rotation speed, and use spiral scanning to ensure full coverage of the scanning. When the probe reaches the end position of the upper end surface, wait for the ferrule to rotate for one circle, and then turn off sensor 3. When the probe moves to the starting position of the outer diameter surface, turn on sensor 2. After the ferrule rotates for one circle, control the probe to move from the starting position to the scanning end position along the outer diameter surface, set the moving speed to match the ferrule rotation speed, and use spiral scanning to ensure full coverage of the scanning. After the head reaches the end position of the outer diameter surface, wait for the ring to rotate for one circle and turn off sensor 2; when the probe moves to the starting position of the lower end surface, turn on sensor 1, and after the ring rotates for one circle, control the probe to move from the starting position to the scanning end position along the lower end surface, set the moving speed to match the ring rotation speed, and ensure full coverage of the scan in the form of spiral scanning. After the probe reaches the end position of the lower end surface, wait for the ring to rotate for one circle and turn off sensor 1; and so on, complete the scanning of all surfaces; the probe returns to a safe position and turns off the eddy current scanning record; the G code execution file includes general commands and Custom commands; the general commands include scanning start point, end point, straight line, arc, rotation and delay, and the custom commands include scanning start control, scanning shutdown control, probe opening, probe closing, and eddy current detection parameter setting; the custom commands are interspersed with the general commands to form a complete scanning path; the G code execution file is stored in the folder specified by the IPC hard disk; the G code execution file is sent to the PLC system through the configuration software installed in the IPC, and stored in the storage medium of the PLC system to control the file interaction between the PLC and the IPC; Step 2: Display and edit G code execution files: The operator browses the files in the PLC system storage medium through the configuration software on the IPC, selects the corresponding G code execution file, and reads, edits, and saves it as needed; Step 3: Convert into PLC executable commands through PLC compilation: The PLC system executes the motion path and control commands, controls the probe through horizontal, vertical and rotation axes to perform contour scanning along different surfaces of the ring, controls the eddy current flaw detection system to start detection before the start of the scan, starts the probe at the starting position of each scan area, collects eddy current data, closes the probe at the end position of each scan area, stops collecting eddy current data, closes the scan record at the end of the scan, and switches the detection parameters as needed during the scan.

[0020] The PLC compilation process is: Step 1, G code file processing: The PLC system reads data from the selected G code execution file and transfers it line by line to the PLC data buffer area; the storage medium and the data buffer area can exchange data through the G code file processing module; Step 2, program parser: (1) Check whether the syntax and semantics of the G code program written into the data buffer area conform to the rules; (2) The G code program written into the data buffer is translated through the language package set in the PLC system, and the G code is converted into the PLC executable language SCL; the language set in the PLC system includes general commands and custom commands, and the custom commands are commands defined according to the needs of eddy current detection; Step 3: Generate an executable motion path: The PLC reads the compiled PLC executable language SCL from the program parser, generates an executable motion path, and sends it to the IPC configuration software for display, showing the current path and active line.

Claims

1. A G-code-based eddy current profiling scanning control method, characterized in that: The eddy current profiling scanning control method writes the corresponding process parameters for eddy current profiling scanning of irregular parts in the form of G code to form a G code execution file, and the G code execution files corresponding to each model are independently set, each of the G code execution files is parsed by the PLC system to generate a corresponding PLC executable language, converted into a PLC executable command, and the PLC system is used to control the operation of each servo system so that the eddy current probe performs profiling scanning along the surface of the workpiece; and the state and result of the command execution are fed back to the configuration software to display the current path and activation line; a closed loop is formed between the G code execution file and the corresponding servo system, and independent control is performed; the details are as follows: Step 1, generate G code execution file: draw or load workpiece drawings through CAD / CAM software on IPC, combine corresponding process parameters, determine the area to be scanned, scanning order, scanning speed, and generate G code execution file according to the confirmed scanning path; the G code execution file includes general commands and custom commands; the general commands include scanning starting point, end point, straight line, arc, rotation and delay, and the custom commands include scanning start control, scanning shutdown control, probe opening, probe closing, eddy current detection parameter setting; the custom commands and the general commands are interspersed to form a complete scanning path; the G code execution file is stored in the folder specified by the IPC hard disk; the G code execution file is sent to the PLC system through the configuration software installed in the IPC, and stored in the storage medium of the PLC system to control the file interaction between the PLC and the IPC; Step 2: Display and edit G code execution files: The operator browses the files in the PLC system storage medium through the configuration software on the IPC, selects the corresponding G code execution file, and reads, edits, and saves it as needed; Step 3, G code file processing: The PLC system reads data from the selected G code execution file and transfers it line by line to the PLC data buffer area; the storage medium and the data buffer area can exchange data through the G code file processing module; Step 4. Program parser: (1) Check whether the syntax and semantics of the G code program written into the data buffer area conform to the rules; (2) The G code program written into the data buffer is translated through the language package set in the PLC system, and the G code is converted into the PLC executable language SCL; the language set in the PLC system includes general commands and custom commands, and the custom commands are commands defined according to the needs of eddy current detection; Step 5. Generate executable motion path: PLC reads the compiled PLC executable language SCL from the program parser, generates executable motion path, and sends it to the IPC configuration software for display, showing the current path and active line; Step 6: Convert to PLC executable commands: The PLC system executes the motion path and control commands, controls the probe through the horizontal, vertical and rotation axes to perform contour scanning along different surfaces of the ring, controls the eddy current flaw detection system to start scanning before the start of scanning, opens the probe at the starting position of each scanning area, collects eddy current data, closes the probe at the end position of each scanning area, stops collecting eddy current data, closes the scanning record at the end of the scanning, and switches the detection parameters as needed during the scanning process.

2. The eddy current profiling control method based on G code according to claim 1, characterized in that: The PLC system is equipped with a three-axis control process object, an absolute position feedback module, an incremental pulse feedback module, and an IO module. The three-axis control process object controls the servo drive system through an industrial switch, the absolute position feedback module collects absolute magnetic encoder signals in real time, the incremental pulse feedback module is connected to the electronic handwheel, and the IO module is connected to the input and output digital signals.

3. The eddy current profiling control method based on G code according to claim 1, characterized in that: The servo system includes a servo driver, a servo motor, an absolute magnetic encoder, a synchronous belt, and a reducer. The servo system is the actuator of the entire system. The servo driver drives the servo motor to operate according to the PLC instructions, drives the motion mechanism to operate through the reducer or synchronous belt mechanism, and realizes precise position control through the feedback signal of the absolute magnetic encoder.

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