Tool changing method for realizing black lamp production

Abstract

The invention relates to the condition of a monitoring tool, in particular to a tool changing method for realizing black light production, which is used for solving the problems that an existing tool changing method for a production line depends on early warning logic, so that a tool changing strategy is limited to passive response, and frequent tool changing or low tool utilization rate possibly occurs in a scene with large service life difference. And an emergency strategy that the service life of the cutter is depleted in advance in a black lamp time period is not set. According to the tool changing method for achieving black light production, whether the difference value between the highest service life and the lowest service life is larger than a preset threshold value or not is judged, the lowest service life or daily production is selected as a standard, and the service life of a tool is optimized to be integral multiples of the standard; the minimum tool changing period is calculated, and it is ensured that the tool changing period is reasonably matched with the black lamp period; and if the minimum tool changing period is too short, further optimization is carried out through sister tool allocation.

Description

Technical Field

[0001] The invention relates to the status of a monitoring tool, and in particular to a tool changing method for realizing dark light production. Background Art

[0002] In the machinery manufacturing industry, tool life management of CNC machine tools is a key link that affects production efficiency and product quality. The traditional tool replacement method mainly relies on the workers' experience and judgment, which has the following limitations:

[0003] (1) Uncertainty and inefficiency: The subjectivity of workers’ experience makes it impossible to accurately control the tool change time, which leads to the risk of changing the tool too early or too late. Changing the tool too early increases production costs, while changing it too late may affect product quality and increase the scrap rate.

[0004] (2) Challenges of automation requirements: With the development of dark factories (i.e., unmanned factories), the traditional tool changing mode is difficult to meet the requirements of highly automated production; dark factories require the tool changing process to have higher predictability and planning to avoid frequent and unscheduled operation interruptions.

[0005] Chinese patent CN115344007A discloses an intelligent tool changing method, which sets a tool changing time period and a blackout time period, and judges the remaining processing time of the tool and the continuous operation time of the production line during the tool changing time period. When replacing a tool whose remaining life is lower than the set warning life value, it also replaces a tool whose remaining processing time is less than the continuous operation time of the production line during the tool changing time period; in addition, before entering the blackout time period, it replaces a tool whose remaining processing time is less than the continuous operation time of the production line during the blackout time period; this patent replaces the tools in a centralized manner during the tool changing time period, reduces the frequency of tool changing, and increases the production line start-up rate, making the tool changing time period and continuous operation time flexible and controllable. However, this method relies on warning logic, which results in the tool changing strategy being limited to passive response. In scenarios with large differences in life span, there may be problems with frequent tool changing or low tool utilization, and no emergency strategy is set for the tool to run out of life in advance during the blackout time period. Summary of the invention

[0006] The purpose of the present invention is to solve the shortcomings that the existing tool changing method for production lines relies on early warning logic, resulting in the tool changing strategy being limited to passive response. In scenarios where the life span difference is large, problems such as frequent tool changing or low tool utilization may occur, and there is no emergency strategy for the tool to run out of life in advance during the dark time period. Instead, a tool changing method that realizes dark production is provided.

[0007] In order to solve the deficiencies of the above-mentioned prior art, the present invention provides the following technical solutions:

[0008] A tool changing method for realizing dark light production, which is special in that it includes the following steps:

[0009] Step 1: Collect the lifespan of all tools on a production line and construct a lifespan set S = {L1, L2, ..., Ln}, where n is the number of tool types, n≥3; and divide the operation time period of the production line into a tool change period and a dark period. The tool change period refers to a period when workers can change tools at any time, and the dark period refers to a period when no workers are performing tool change operations;

[0010] Step 2: Determine the maximum life L of all tools in the production line max With the minimum life span L min Is the difference ΔL greater than the preset life difference ΔL′? If so, the minimum life L min As a benchmark, optimize the life of the remaining tools to an integer multiple of the benchmark, obtain the optimized life of all tools, and then execute step 3; otherwise, take the daily production volume P of the production line as a benchmark, optimize the life of all tools to an integer multiple of the benchmark, obtain the optimized life of all tools, and then execute step 3;

[0011] Step 3: Set the minimum tool change cycle T during the tool change period min Optimize the minimum life of all tools and determine the minimum tool change cycle T min Is it greater than or equal to the planned dark time period T? black , if yes, go directly to step 5; otherwise go to step 4;

[0012] Step 4: If the minimum life span L is used in step 2 min As a benchmark, the replacement frequency f of the i-th tool is calculated based on the total number of sister tools that can be stored X. i , and allocate the number of sister knives according to the replacement frequency of each tool, and then execute step 5; if the daily production volume P of the production line is used as the benchmark in step 2, then according to the total number of sister knives that can be stored X, the daily usage of the i-th tool is calculated as U i , and allocate the number of sister knives according to the daily usage of each knife, and then execute step 5;

[0013] Step 5, setting a real-time monitoring command, a tool change prediction command and an abnormal prompt command in the TLM system; the real-time monitoring command is used to display the remaining tool change time; the tool change prediction command is used to remind the worker to prepare a spare tool in advance through the TLM system when the remaining tool change time is less than or equal to the safety threshold a; the abnormal prompt command is to automatically replace the sister tool through the TLM system or remind the worker to change the tool separately if the tool runs out of life in advance during the tool change period and the dark period;

[0014] Step 6: Each time the production line starts production, the TLM system automatically executes the real-time monitoring command, tool change prediction command and abnormal prompt command. During the tool change period, the worker follows the minimum tool change cycle T set in step 3. min Perform synchronous tool change operations until the production line completes the production.

[0015] Furthermore, in step 2, the preset life difference ΔL′ is as follows:

[0016] ΔL′=ω1ΔL+ω2μ

[0017] Where μ is the average life of all tools in the production line, and ω1 and ω2 are weight coefficients.

[0018] Furthermore, in step 4, the calculation of the replacement frequency f of the i-th tool i , and the number of sister knives is allocated according to the replacement frequency of each tool:

[0019] Calculate the replacement frequency f of the i-th tool i :

[0020] f i =T min / L (i)

[0021] Among them, L (i) is the optimized life of the i-th tool;

[0022] Calculate the number of sister tools A of the i-th tool i as follows:

[0023]

[0024] Among them, f j The replacement frequency of the j-th tool, j ranges from 1 to n.

[0025] Further, in step 4, the daily usage of the i-th tool is calculated as U i , and the number of sister knives is allocated according to the daily usage of each knife:

[0026] Calculate the daily usage of the i-th tool as U i :

[0027] U i =P / L (i)

[0028] Calculate the number of sister tools A of the i-th tool i as follows:

[0029]

[0030] Among them, Uj The daily usage of the j-th tool, where j ranges from 1 to n.

[0031] Furthermore, in step 5, the implementation steps of the abnormal prompt command are as follows:

[0032] Step a, the TLM system detects that the tool life is exhausted in advance, and determines whether it is a black light period. If so, execute step b; otherwise, execute step c;

[0033] Step b: handling abnormalities during dark hours;

[0034] Step b1, determine whether the tool has a sister tool, if so, automatically dispatch the sister tool for replacement, and then execute step b2; otherwise, suspend production and notify the worker to change the tool, waiting for the tool change period;

[0035] Step b2, calculate the sum of the service life of the replaced sister knife and its remaining sister knives, and determine whether the sum of the service life can cover the remaining black light period. If so, continue normal production; otherwise, when the sum of the service life is 0, automatically enter the knife replacement period and continue normal production;

[0036] Step c: abnormal handling during tool change period;

[0037] Step c1, determine whether the tool has a sister tool, if so, automatically dispatch the sister tool for replacement, and then execute step c2; otherwise, suspend production and notify the worker to change the tool, and then execute step c2;

[0038] Step c2: Calculate the life L of the new replacement tool (new) , determine the life span L (new) Can it cover the current tool change cycle? If yes, then continue normal production; otherwise, the life span L (new) When it is 0, the tool is changed in advance and then normal production continues.

[0039] Compared with the prior art, the present invention has the following beneficial effects:

[0040] (1) The present invention provides a tool changing method for realizing dark-light production. By judging whether the difference between the maximum life and the minimum life is greater than a preset threshold, the minimum life or daily production volume is selected as a benchmark, and the tool life is optimized to an integer multiple of the benchmark; and the minimum tool changing cycle is calculated to ensure that the tool changing period and the dark-light period are reasonably matched; if the minimum tool changing cycle is too short, it is further optimized by allocating sister tools; the present invention realizes centralized, intelligent and efficient tool management through data analysis, intelligent optimization and automated execution, and is suitable for highly automated manufacturing scenarios such as dark-light factories.

[0041] (2) The present invention is based on data-driven tool life analysis and optimization, combined with the TLM system to achieve real-time monitoring and predictive reminders, eliminating the uncertainty of manual decision-making.

[0042] (3) The present invention optimizes tool utilization and reduces tool waste through centralized tool change and sister tool management. In addition, the method of the present invention can be adapted to different production scales and process requirements through simple adjustments, which is convenient for expansion and promotion. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 This is a flow chart of steps 1 to 5 of an embodiment of a tool changing method for achieving dark light production according to the present invention. DETAILED DESCRIPTION

[0044] The present invention will be further described below in conjunction with the accompanying drawings and exemplary embodiments.

[0045] Reference Figure 1 , a tool changing method for realizing dark light production, comprising the following steps:

[0046] Step 1: Collect the lifespan of all tools on a production line and construct a lifespan set S = {L1, L2, ..., Ln}, where n is the number of tool types, n≥3; and divide the operation time period of the production line into a tool change period and a dark period. The tool change period refers to a period when workers can change tools at any time, and the dark period refers to a period when no workers are performing tool change operations;

[0047] Step 2: Determine the maximum life L of all tools in the production line max With the minimum life span L min Is the difference ΔL greater than the preset life difference ΔL′? If so, the minimum life L min As a benchmark, optimize the life of the remaining tools to an integer multiple of the benchmark, obtain the optimized life set S′ of all tools, and then execute step 3; otherwise, take the daily production volume P of the production line as a benchmark, optimize the life of all tools to an integer multiple of the benchmark, obtain the optimized life of all tools, and then execute step 3;

[0048] The preset life difference ΔL′ depends on the specific requirements of the production line and the characteristics of tool life distribution; for example, the maximum life L max With the minimum life span L min The difference ΔL and the average value are weighted:

[0049] ΔL′=ω1ΔL+ω2μ

[0050] Where μ is the average life of all tools in the production line, ω1 and ω2 are weight coefficients, which are adjusted according to the needs of the production line;

[0051] Step 3: Set the minimum tool change cycle T during the tool change period min Optimize the minimum life of all tools and determine the minimum tool change cycle T minIs it greater than or equal to the planned dark time period T? black If yes, it means that the production line does not need to change the tool during the dark period, and go to step 5; otherwise, it means that the tool life needs to be further optimized, and go to step 4;

[0052] Step 4: If the minimum life span L is used in step 2 min As a benchmark, the replacement frequency f of the i-th tool is calculated based on the total number of sister tools that can be stored X. i :

[0053] f i =T min / L (i)

[0054] Among them, L (i) is the optimized life of the i-th tool;

[0055] Calculate the number of sister tools A of the i-th tool i as follows:

[0056]

[0057] Among them, f j The replacement frequency of the jth tool, j ranges from 1 to n;

[0058] Then proceed to step 5;

[0059] If the daily production volume P of the production line is used as the benchmark in step 2, then according to the total number of sister knives that can be stored X, the daily usage of the i-th tool is calculated as U i :

[0060] U i =P / L (i)

[0061] Calculate the number of sister tools A of the i-th tool i as follows:

[0062]

[0063] Among them, U j The daily usage of the jth tool, where j ranges from 1 to n;

[0064] Then proceed to step 5;

[0065] Step 5, set up real-time monitoring commands, tool change prediction commands and abnormal prompt commands in the TLM system; the real-time monitoring command is to use the TLM system to monitor the remaining life of each tool, and multiply the remaining life by the cutting time to generate the remaining tool change time for guiding the centralized tool change preparation; the tool change prediction command is to remind the worker to prepare the spare tool in advance through the TLM system when the remaining tool change time is less than or equal to the safety threshold a; the abnormal prompt command is to automatically prompt through the TLM system when the tool life is exhausted prematurely (such as unexpected wear)

[0066] The implementation steps of the abnormal prompt command are as follows:

[0067] Step a, the TLM system detects that the tool life is exhausted in advance, and determines whether it is a black light period. If so, execute step b; otherwise, execute step c;

[0068] Step b: handling abnormalities during dark hours;

[0069] Step b1, determine whether the tool has a sister tool, if so, automatically dispatch the sister tool in the tool magazine for replacement, and then execute step b2; otherwise, suspend production and notify the worker to change the tool, waiting for the tool change period;

[0070] Step b2, calculate the sum of the service life of the replaced sister knife and its remaining sister knives, and determine whether the sum of the service life can cover the remaining black light period. If so, continue normal production; otherwise, when the sum of the service life is 0, automatically enter the knife replacement period and continue normal production;

[0071] Step c: abnormal handling during tool change period;

[0072] Step c 1. Determine whether the tool has a sister tool. If so, automatically dispatch the sister tool in the tool magazine for replacement, and then execute step c2; otherwise, suspend production and notify the worker to change the tool, and then execute step c2;

[0073] Step c2: Calculate the life L of the new replacement tool (new) , determine the life span L (new) Can it cover the current tool change cycle? If yes, then continue normal production; otherwise, the life span L (new) When it is 0, the tool is changed in advance and then normal production continues;

[0074] Step 6. Each time the production line starts production, the TLM system automatically executes the real-time monitoring command, tool change prediction command and abnormal prompt command. During the tool change period, the worker performs synchronous tool change operations according to the minimum tool change cycle set in step 3 until the production line completes the production.

[0075] In this embodiment, for the first production line, the lifespan set S = {50, 110, 148, 208, 298}, L min=50,L max =298, ΔL=248, σ≈85.1;

[0076] Since ΔL<ΔL′=500, the first production line will have the minimum life L min As a benchmark, the remaining tool life is optimized to an integer multiple of the benchmark, and the optimized life set S′={50, 100, 150, 200, 300} is obtained;

[0077] Set the minimum tool change cycle T during the tool change period min The minimum value of 50 for optimizing the life of all tools is 50, that is, the tool change is performed every 50 pieces. The tool change planning during the tool change period is shown in Table 1;

[0078] Table 1

[0079] Type 1 tool Type 2 tool Type 3 tool Type 4 tool Type 5 tool 1 Change 2-Change 1 Change 3Swap 1 Change 4 Change 2-Change 1 Change 5 Change 6 Swap 3Swap 2 Change 1 Change

[0080] For the second production line, the lifespan set S = {95, 1110, 1958, 2008, 2980}, L min =95,L max =2980, ΔL=2885;

[0081] Since ΔL>ΔL′=500, the first production line takes the daily production volume P (100 pieces) of the production line as the benchmark, optimizes the life of the remaining tools to an integer multiple of the benchmark, and obtains the optimized life set S′={100,1100,1900,2000,3000};

[0082] Set the minimum tool change cycle T during the tool change period min The minimum value of the optimized life of all tools is 100, that is, the tool is replaced every 100 pieces processed. The tool change planning during the tool change period is shown in Table 2;

[0083] Table 2

[0084] Type 1 tool Type 2 tool Type 3 tool Type 4 tool Type 5 tool 1 Change 11 Exchange 1 Change 19 Exchange 1 Change 20 Exchange 1 Change 30 Exchange 1 Change

[0085] The two benchmark options (minimum life or daily production) enable the embodiments of the present invention to flexibly adapt to complex production lines with large differences in tool life or efficient production lines with similar tool life.

Claims

1. A tool changing method for realizing dark light production, characterized in that: The steps include: Step 1: Collect the lifespan of all tools on a production line and construct a lifespan set S = {L1, L2, ..., Ln}, where n is the number of tool types, n≥3; and divide the operation time period of the production line into a tool change period and a dark period. The tool change period refers to a period when workers can change tools at any time, and the dark period refers to a period when no workers are performing tool change operations; Step 2: Determine the maximum life L of all tools in the production line max With the minimum life span L min Is the difference ΔL greater than the preset life difference ΔL′? If so, the minimum life L min As a benchmark, the life of the remaining tools is optimized to an integer multiple of the benchmark to obtain the optimized life of all tools, and then step 3 is executed; Otherwise, the daily production volume P of the production line is taken as the benchmark, and the life of all tools is optimized to an integer multiple of the benchmark to obtain the optimized life of all tools, and then step 3 is executed; Step 3: Set the minimum tool change cycle T during the tool change period min Optimize the minimum life of all tools and determine the minimum tool change cycle T min Is it greater than or equal to the planned dark time period T? black , if yes, go directly to step 5; otherwise go to step 4; Step 4: If the minimum life span L is used in step 2 min As a benchmark, the replacement frequency f of the i-th tool is calculated based on the total number of sister tools that can be stored X. i , and allocate the number of sister knives according to the replacement frequency of each tool, and then execute step 5; if the daily production volume P of the production line is used as the benchmark in step 2, then according to the total number of sister knives that can be stored X, the daily usage of the i-th tool is calculated as U i , and allocate the number of sister knives according to the daily usage of each knife, and then execute step 5; Step 5, setting a real-time monitoring command, a tool change prediction command and an abnormal prompt command in the TLM system; the real-time monitoring command is used to display the remaining tool change time; the tool change prediction command is used to remind the worker to prepare a spare tool in advance through the TLM system when the remaining tool change time is less than or equal to the safety threshold a; the abnormal prompt command is to automatically replace the sister tool through the TLM system or remind the worker to change the tool separately if the tool runs out of life in advance during the tool change period and the dark period; Step 6: Each time the production line starts production, the TLM system automatically executes the real-time monitoring command, tool change prediction command and abnormal prompt command. During the tool change period, the worker follows the minimum tool change cycle T set in step 3. min Perform synchronous tool change operation until the production line completes the production.

2. A tool changing method for realizing dark light production according to claim 1, characterized in that: In step 2, the preset life difference ΔL′ is as follows: ΔL′=ω1ΔL+ω2μ Where μ is the average life of all tools in the production line, and ω1 and ω2 are weight coefficients.

3. A tool changing method for realizing dark light production according to claim 1 or 2, characterized in that: In step 4, the replacement frequency f of the i-th tool is calculated i , and the number of sister knives is allocated according to the replacement frequency of each tool: Calculate the replacement frequency f of the i-th tool i : f i =T min / L (i) Among them, L (i) is the optimized life of the i-th tool; Calculate the number of sister tools A of the i-th tool i as follows: Among them, f j The replacement frequency of the j-th tool, j ranges from 1 to n.

4. A tool changing method for realizing dark light production according to claim 3, characterized in that: In step 4, the daily usage of the i-th tool is calculated as U i , and the number of sister knives is allocated according to the daily usage of each knife: Calculate the daily usage of the i-th tool as U i : The i =P / L (i) Calculate the number of sister tools A of the i-th tool i as follows: Among them, U j The daily usage of the j-th tool, where j ranges from 1 to n.

5. A tool changing method for realizing dark light production according to claim 4, characterized in that: In step 5, the implementation steps of the abnormal prompt command are as follows: Step a, the TLM system detects that the tool life is exhausted in advance, and determines whether it is a black light period. If so, execute step b; otherwise, execute step c; Step b: handling abnormalities during dark hours; Step b1, determine whether the tool has a sister tool, if so, automatically dispatch the sister tool for replacement, and then execute step b2; otherwise, suspend production and notify the worker to change the tool, waiting for the tool change period; Step b2, calculate the sum of the service life of the replaced sister knife and its remaining sister knives, and determine whether the sum of the service life can cover the remaining black light period. If so, continue normal production; otherwise, when the sum of the service life is 0, automatically enter the knife replacement period and continue normal production; Step c: abnormal handling during tool change period; Step c1, determine whether the tool has a sister tool, if so, automatically dispatch the sister tool for replacement, and then execute step c2; otherwise, suspend production and notify the worker to change the tool, and then execute step c2; Step c2: Calculate the life L of the new replacement tool (new) , determine the life span L (new) Whether the current tool change cycle can be covered, if so, continue normal production; Otherwise, the life span L (new) When it is 0, the tool is changed in advance and then normal production continues.

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