A tool changing method for realizing black light production

Abstract

The present application relates to monitoring the condition of a tool, and in particular to a tool changing method for realizing black light production, which is used to solve the problem that the existing tool changing method for production line relies on early warning logic, resulting in that the tool changing strategy is limited to passive response, in the scene of large life difference, frequent tool changing or low tool utilization may occur, and there is no emergency strategy for the tool to be exhausted in advance in the black light period. The tool changing method for realizing black light production selects the minimum life or daily production as the reference by judging whether the difference between the maximum life and the minimum life is greater than the preset threshold, optimizes the tool life to be an integer multiple of the reference; and calculates the minimum tool changing period to ensure that the tool changing period and the black light period are reasonably matched; if the minimum tool changing period is too short, further optimization is performed through sister tool distribution.

Description

TECHNICAL FIELD

[0001] The present application relates to monitoring the condition of a tool, in particular to a tool changing method for realizing black light production. BACKGROUND

[0002] In the mechanical manufacturing industry, tool life management of numerical control machine tools is a key link affecting production efficiency and product quality. The traditional tool changing method mainly relies on the experience of workers to make judgments, which has the following limitations:

[0003] (1) Uncertainty and inefficiency: the subjectivity of worker experience makes it impossible to accurately control the tool changing time, and there is a risk of replacing the tool too early or too late; replacing the tool too early increases production costs, and replacing it too late may affect product quality and increase scrap rates;

[0004] (2) Challenge of automation needs: with the development of black light factories (i.e. unmanned factories), the traditional tool changing mode cannot meet the requirements of highly automated production; black light factories require the tool changing process to have higher predictability and planning, avoiding frequent and indefinite operation interruptions.

[0005] Chinese patent CN115344007A discloses an intelligent tool changing method, which sets a tool changing time period and a black light time period, and in the tool changing time period, the tool with a remaining life lower than a set early warning life value and the tool with a remaining processing time less than the continuous running time of the production line in the tool changing time period are replaced at the same time; in addition, before entering the black light time period, the tool with a remaining processing time less than the continuous running time of the production line in the black light time period is replaced; this patent concentrates on replacing tools in the tool changing time period, reduces the frequency of tool changing, improves the production line start-up rate, and makes the tool changing time period and the continuous running time flexible and controllable. However, this method relies on early warning logic, resulting in a tool changing strategy that is limited to passive response, and in scenarios with large differences in tool life, there may be frequent tool changes or low tool utilization, and there is no emergency strategy for tools running out of life in the black light time period. SUMMARY

[0006] The purpose of the present application is to solve the problem of existing tool changing methods for production lines that rely on early warning logic, resulting in a tool changing strategy that is limited to passive response, and in scenarios with large differences in tool life, there may be frequent tool changes or low tool utilization, and there is no emergency strategy for tools running out of life in the black light time period, and to provide a tool changing method for realizing black light production.

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

[0008] The application discloses a tool changing method for realizing black light production, and has the special steps of:

[0009] Step 1, collecting the life of all tools on a production line, and constructing a life set S={L1, L2,..., Ln}, wherein n is the number of tool types, n>=3; and dividing the running time period of the production line into a tool changing period and a black light period, wherein the tool changing period refers to a period in which workers can change tools at any time, and the black light period refers to a period in which no workers change tools;

[0010] Step 2, judging whether the difference AL between the highest life L max and the lowest life L min in all tools of the production line is greater than a preset life difference AL', if yes, taking the lowest life L min as a reference, optimizing the life of the remaining tools to be integer multiples of the reference, obtaining the optimized life of all tools, and then executing step 3; otherwise, taking the daily production P of the production line as a reference, optimizing the life of all tools to be integer multiples of the reference, obtaining the optimized life of all tools, and then executing step 3;

[0011] Step 3, setting the minimum tool changing period T min of the tool changing period as the minimum value of the optimized life of all tools, and judging whether the minimum tool changing period T min is greater than or equal to the planned black light period T black , if yes, directly executing step 5; otherwise, executing step 4;

[0012] Step 4, if the lowest life L min is taken as the reference in step 2, the replacement frequency f i of the i-th tool is calculated according to the total number X of the storable sister tools, and the number of sister tools is distributed according to the replacement frequency of each tool, and then step 5 is executed; if the daily production P of the production line is taken as the reference in step 2, the daily use U i of the i-th tool is calculated according to the total number X of the storable sister tools, and the number of sister tools is distributed according to the daily use of each tool, and then step 5 is executed;

[0013] Step 5, setting real-time monitoring commands, tool changing prediction commands and abnormal prompt commands in a TLM system; the real-time monitoring commands are used for displaying the remaining tool changing time; the tool changing prediction commands are used for reminding workers to prepare spare tools in advance through the TLM system when the remaining tool changing time is less than or equal to a safety threshold a; and the abnormal prompt commands are used for automatically replacing sister tools or prompting workers to change tools alone through the TLM system when the tool changing period and the black light period appear tool life exhaustion in advance;

[0014] Step 6, after each production, the TLM system automatically executes the real-time monitoring command, the tool change prediction command and the abnormal prompt command, and the worker changes the tool according to the minimum tool change period T set in step 3 during the tool change period min Synchronous tool change operation is performed until the production line completes the production.

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

[0016] ΔL' = ω1ΔL + ω2μ

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

[0018] Further, in step 4, the replacement frequency f of the i-th tool is calculated i , and the number of sister tools is allocated according to the replacement frequency of each tool, which is specifically:

[0019] The replacement frequency f of the i-th tool is calculated i :

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

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

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

[0023]

[0024] Wherein, f j is the replacement frequency of the j-th tool, and j takes a value of 1 to n.

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

[0026] The daily usage U of the i-th tool is calculated as follows: i

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

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

[0029]

[0030] Wherein, U​​​j The daily use amount of the jth tool, j is 1-n.

[0031] Further, 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, judges whether it is a black light period, if yes, step b is executed; otherwise, step c is executed.

[0033] Step b, black light period abnormal processing;

[0034] Step b1, judge whether the tool has a sister tool, if yes, automatically schedule the sister tool to replace, and then execute step b2; otherwise, pause production and notify the worker to change the tool, and wait to enter the tool changing period;

[0035] Step b2, calculate the total life of the replaced sister tool and its remaining sister tool, judge whether the total life can cover the remaining black light period, if yes, continue normal production; otherwise, when the total life is 0, automatically enter the tool changing period, and continue normal production;

[0036] Step c, tool changing period abnormal processing;

[0037] Step c1, judge whether the tool has a sister tool, if yes, automatically schedule the sister tool to replace, and then execute step c2; otherwise, pause production and notify the worker to change the tool, and then execute step c2;

[0038] Step c2, calculate the life L of the newly replaced tool (new) , judge whether the life L (new) can cover the current tool changing period, if yes, continue normal production; otherwise, when the life L (new) is 0, change the tool in advance, and then continue normal production.

[0039] Compared with the prior art, the beneficial effects of the present application are:

[0040] (1) The tool changing method for realizing black light production of the present application selects the minimum life or the daily production as the reference by judging whether the difference between the maximum life and the minimum life is greater than the preset threshold, optimizes the tool life to an integer multiple of the reference, and calculates the minimum tool changing period to ensure that the tool changing period and the black light period are reasonably matched; if the minimum tool changing period is too short, it is further optimized through sister tool distribution; the present application realizes the centralization, intelligence and high efficiency of tool management through data analysis, intelligent optimization and automatic execution, and is suitable for highly automated manufacturing scenes such as black light factories.

[0041] (2) The tool life analysis and optimization of the present application are based on data driving, and realize real-time monitoring and prediction reminding in combination with the TLM system, which eliminates the uncertainty of manual decision making.

[0042] (3)The tool utilization rate is optimized by concentrating tool changing and sister tool management, tool waste is reduced, and the method can be adapted to different production scales and process requirements by simple adjustment, facilitating expansion and popularization. BRIEF DESCRIPTION OF DRAWINGS

[0043] Figure 1 A flowchart for steps 1 to 5 of an embodiment of the tool changing method for black light production of the present application. DETAILED DESCRIPTION

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

[0045] REFERENCE Figure 1 A tool changing method for black light production includes the following steps:

[0046] Step 1, collect the life of all tools on a production line, and construct a life set S = {L1, L2,..., Ln}, where n is the number of tool types, n ≥ 3; and divide the running time period of the production line into a tool changing period and a black light period, the tool changing period means that workers can perform tool changing operation at any time, and the black light period means that no workers perform tool changing operation;

[0047] Step 2, determine whether the difference ΔL between the highest life L max and the lowest life L min of all tools on the production line is greater than a preset life difference ΔL', if yes, take the lowest life L min as a reference, optimize the life of the remaining tools to be integer multiples of the reference, obtain an optimized life set S' of all tools, and then execute step 3; otherwise, take the daily production P of the production line as a reference, optimize the life of all tools to be integer multiples of the reference, obtain an optimized life of all tools, and then execute step 3;

[0048] The preset life difference ΔL' depends on the specific needs of the production line and the characteristics of the tool life distribution; for example, the difference ΔL between the highest life L max and the lowest life L min and the average value can be weighted and calculated:

[0049] ΔL' = ω1ΔL + ω2μ

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

[0051] Step 3, set the minimum tool changing period T min for all tool optimized life as the minimum value, and determine the minimum tool changing period T minIs greater than or equal to the planned black light period T black If yes, it means that the production line does not need to change the tool during the black light period, and step 5 is executed; otherwise, it means that the tool life needs to be further optimized, and step 4 is executed;

[0052] Step 4, if the lowest life L min is taken as the reference in step 2, then the replacement frequency f i of the i-th tool is calculated according to the total number of storable sister tools X

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

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

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

[0056]

[0057] Wherein, f j is the replacement frequency of the j-th tool, and j takes a value of 1-n;

[0058] Then step 5 is executed;

[0059] If the daily production P of the production line is taken as the reference in step 2, then the daily use U i of the i-th tool is calculated according to the total number of storable sister tools X

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

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

[0062]

[0063] Wherein, U j is the daily use of the j-th tool, and j takes a value of 1-n;

[0064] Then step 5 is executed;

[0065] Step 5, setting real-time monitoring command, tool replacement prediction command and abnormal prompt command in the TLM system; the real-time monitoring command is to monitor the remaining life of each tool by using the TLM system, and to generate the remaining tool replacement time by multiplying the remaining life and the cutting time, which is used to guide the centralized tool replacement preparation; the tool replacement prediction command is to remind the worker to prepare the spare tool in advance through the TLM system when the remaining tool replacement time is less than or equal to the safety threshold a; the abnormal prompt command is used to automatically prompt through the TLM system when the tool life is exhausted in advance (such as accidental 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, judges whether it is a black light period, if yes, step b is executed; otherwise, step c is executed;

[0068] Step b, black light period abnormality processing;

[0069] Step b1, judging whether the tool has a sister tool, if yes, the sister tool in the tool magazine is automatically dispatched to replace, and then step b2 is executed; otherwise, the production is suspended and the worker is notified to replace the tool, and then the changeover period is entered;

[0070] Step b2, calculating the life sum of the replaced sister tool and its remaining sister tool, judging whether the life sum can cover the remaining black light period, if yes, the normal production is continued; otherwise, when the life sum is 0, the changeover period is automatically entered, and the normal production is continued;

[0071] Step c, changeover period abnormality processing;

[0072] Step c1, judging whether the tool has a sister tool, if yes, the sister tool in the tool magazine is automatically dispatched to replace, and then step c2 is executed; otherwise, the production is suspended and the worker is notified to replace the tool, and then step c2 is executed;

[0073] Step c2, calculating the life L (new) of the newly replaced tool (new) , judging whether the life L (new) can cover the current tool replacement period, if yes, the normal production is continued; otherwise, when the life L min is 0, the tool replacement is performed in advance, and then the normal production is continued;

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

[0075] In this embodiment, for the first production line, the life set S = {50, 110, 148, 208, 298}, L min= 50, L max = 95, L min = 2980, AL = 2885;

[0076] Since AL < AL' = 500, the first production line will optimize the life of the remaining tools to be an integer multiple of the minimum life L min As a reference, the life of the remaining tools is optimized to be an integer multiple of the reference, and the optimized life set S' = {50, 100, 150, 200, 300} is obtained;

[0077] The minimum tool change period T min The minimum value of the optimized life of all tools is 50, that is, it is replaced every 50 pieces, and the tool change planning of the tool change period is shown in Table 1;

[0078] Table 1

[0079] First tool Second tool Third tool Fourth tool Fifth tool 1 exchange 2 exchange 1 exchange 3 exchange 1 exchange 4 exchange 2 exchange 1 exchange 5 exchange 6 exchange 3 exchange 2 exchange 1 exchange

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

[0081] Since AL > AL' = 500, the first production line will optimize the life of the remaining tools to be an integer multiple of the minimum life L

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

[0083] Table 2

[0084] First tool Second tool Third tool Fourth tool Fifth tool 1 exchange 11 exchange 1 exchange 19 exchange 1 exchange 20 exchange 1 exchange 30 exchange 1 exchange

[0085] Two reference selection (minimum life or daily production) makes the embodiment of the application flexible to adapt to complex production lines with large tool life difference or efficient production lines with close tool life.

Claims

1. A tool changing method for realizing black light production, characterized by, Comprising the following steps: Step 1, collect the life of all cutters of a production line, and construct a life set S={L1, L2,...,Ln}, where n is the number of cutter types, n≥3; and divide the running time period of the production line into cutter changing period and black light period, the cutter changing period means that workers can change cutters at any time, and the black light period means that no workers change cutters; Step 2: Determine the longest tool life L among all tools on the production line. max With minimum lifespan L min If the difference ΔL is greater than the preset lifespan difference ΔL′, then the minimum lifespan L will be adjusted. min As a baseline, the lifespan of the remaining tools is optimized to an integer multiple of the baseline to obtain the optimized lifespan of all tools, and then step 3 is executed; Otherwise, take the daily production P of the production line as a reference, optimize the life of all cutters to an integer multiple of the reference, obtain the optimized life of all cutters, and then execute step 3; Step 3, set the minimum tool change period T of tool change period min Optimize the minimum value of the life of all tools, and determine the minimum tool change period T min Is greater than or equal to the planned black light period T black If yes, directly execute step 5; otherwise, execute step 4; Step 4: If in Step 2 the minimum lifespan L is used min Based on the total number of sister knives X that can be stored, the replacement frequency f of the i-th type of knife is calculated. i Then, allocate the number of sister tools according to the replacement frequency of each tool, and then proceed to step 5; if the daily production volume P of the production line is used as the benchmark in step 2, then calculate the daily usage of the i-th type of tool as U based on the total number of sister tools X that can be stored. i Then, allocate the number of sister knives according to the daily usage of each knife, and then proceed to step 5; Step 5, set real-time monitoring commands, cutter changing prediction commands and abnormal prompt commands in the TLM system; the real-time monitoring commands are used to display the remaining cutter changing time; the cutter changing prediction commands are used to remind workers to prepare spare cutters in advance through the TLM system when the remaining cutter changing time is less than or equal to the safety threshold a; and the abnormal prompt commands are used to automatically replace sister cutters or prompt workers to change cutters alone when the life of the cutter is exhausted in advance in the cutter changing period and the black light period; Step 6, after each start of production, the TLM system automatically executes the real-time monitoring command, the tool change prediction command and the abnormal prompt command, and the worker changes the tool according to the minimum tool change period T set in step 3 during the tool change period min Synchronous tool change operation is performed until the production line completes the production.

2. The tool changing method for realizing black light production according to claim 1, wherein, In step 2, the preset life difference ΔL' is as follows: ΔL'=ω1ΔL+ω2μ Wherein μ is the average value of the life of all cutters of the production line, and ω1, ω2 are weight coefficients.

3. The tool changing method for producing a black light according to claim 1 or 2, wherein In Step 4, the replacement frequency f of the i-th tool is calculated i and the number of sister tools is allocated according to the replacement frequency of each tool, specifically: calculating the replacement frequency f of the i-th tool i : f i = T min / L (i) wherein L (i) is the optimized lifetime of the i-th tool; Calculating the number of sister tools A for the i-th tool i As follows: wherein f j The replacement frequency of the jth tool, j is 1~n.

4. The tool changing method for realizing black light production according to claim 3, wherein, In Step 4, the daily usage amount of the i-th tool is calculated as U i and the number of sister tools is allocated according to the daily usage amount of each tool, specifically as follows: The daily usage amount of the i-th tool is calculated as U i : U i = P / L (i) Calculating the number of sister tools A for the i-th tool i As follows: wherein U j Daily usage of the jth tool, j = 1 to n.

5. The tool changing method for realizing black light production according to claim 4, wherein, In step 5, the implementation steps of the abnormal prompt commands are as follows: Step a, the TLM system detects that the life of the cutter is exhausted in advance, judges whether it is a black light period, if yes, execute step b; otherwise, step c; Step b, black light period abnormal processing; Step b1, judge whether the cutter has a sister cutter, if yes, automatically dispatch the sister cutter to replace, and then execute step b2; otherwise, pause production and notify workers to change cutters, and wait to turn into the cutter changing period; Step b2, calculate the life sum of the replaced sister cutter and its remaining sister cutter, judge whether the life sum can cover the remaining black light period, if yes, continue normal production; otherwise, when the life sum is 0, automatically turn into the cutter changing period and continue normal production; Step c, cutter changing period abnormal processing; Step c1, judge whether the cutter has a sister cutter, if yes, automatically dispatch the sister cutter to replace, and then execute step c2; otherwise, pause production and notify workers to change cutters, and then execute step c2; Step c2, continue normal production. Step c2, calculate the life L of the new replacement tool (new) , judge the life L (new) whether it can cover the current tool changing period, if yes, continue normal production; Otherwise, the life L (new) When 0, the tool is changed in advance, and then the normal production is continued.

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