Numerical control milling machine remote fault diagnosis system based on Internet of Things

Abstract

The invention relates to a numerical control milling machine remote fault diagnosis system based on the Internet of Things, which is applied to the field of numerical control machine tools and is characterized in that a pre-operation simulation module and a fault elimination guidance module are additionally arranged on the basis of an existing fault diagnosis system, so that technical support is provided for inexperienced workers; the fault solving efficiency and accuracy are effectively improved, a worker can simulate operation in advance by additionally arranging the simulation panel, the worker is helped to modify and adjust in time by monitoring errors in the simulation process, the worker with insufficient experience can be helped to quickly know the operation process in the simulation process, and the fault solving efficiency and accuracy are improved. According to the method, the error rate during actual operation is effectively reduced, then equipment is effectively protected from being damaged, pre-simulation can also promote inexperienced workers to learn autonomously, a positive promoting effect on man-machine interaction is achieved, and therefore the depth of man-machine interaction is effectively improved.

Description

Technical Field

[0001] The present invention relates to a remote fault diagnosis system for a numerically controlled milling machine based on the Internet of Things, and in particular to a remote fault diagnosis system for a numerically controlled milling machine based on the Internet of Things applied in the field of numerically controlled machine tools. Background Art

[0002] Remote fault diagnosis of CNC milling machines refers to the process of diagnosing and troubleshooting faults of CNC milling machines through remote communication technology. Specifically, remote fault diagnosis is achieved by connecting a computer to a remote communication module and using VPN tunnel mode to integrate and transmit data, thereby realizing remote diagnosis and troubleshooting of CNC milling machines. However, the current remote fault diagnosis system cannot achieve good human-computer interaction, which hinders troubleshooting.

[0003] In order to solve the problem of human-computer interaction, a remote diagnosis system on the market adopts the design of building a twin model and has a certain market share.

[0004] The specification of Chinese patent CN202311112875.6 discloses a method and system for remote fault diagnosis of CNC machine tools based on digital twins. The system can perform real-time remote diagnosis of faults of CNC machine tools, and improve the intelligence and detection efficiency of remote fault diagnosis of machine tools. Collect data information of CNC machine tools; the information in the machine tool operation information database is input into the NB-IoT module of the transmission layer through the serial port, and the NB-IoT wireless communication network is transmitted to the NB-IoT cloud platform; the digital twin model of CNC machine tools is constructed based on the real-time operation data and historical data collected by the cloud platform; the CNC machine tools are diagnosed by event detection, the operation status of the CNC machine tools is analyzed, and the attribute data in the status database is compared and analyzed to generate a fault diagnosis report; the remote human-computer interaction interface can receive alarms and obtain diagnosis results.

[0005] The specification of Chinese patent CN201010180487.8 discloses an online monitoring numerical control system based on a network architecture. The embedded online monitoring unit used in the system has a central processor independent of the numerical control system. In the actual processing process, it can ensure that the state monitoring function module and the numerical control instruction function module are independently operated, thereby improving the information processing capabilities of the numerical control and measurement and control systems and ensuring the real-time performance of the numerical control instruction implementation and the measurement and control online monitoring functions. At the same time, the TDNC-Connect information interaction universal call interface used in the present invention emphasizes the openness of the numerical control system and has the characteristics of excellent portability of the numerical control unit. The TDNC-Connect transmission protocol realizes the information interaction between the embedded online monitoring unit and the remote fault diagnosis center, and transfers a large number of tasks of fault diagnosis and intelligent maintenance to the host computer, thereby making up for the limitation of the operation and processing capabilities of the online monitoring unit. The above elements quickly construct a complete monitoring platform for numerical control machine tools with a universal interface that can realize seamless information interaction between the numerical control system and the reconfigurable embedded monitoring unit, and use it as a node or terminal of the equipment information network to realize the status display, fault diagnosis, performance prediction and remote monitoring of high-end numerical control machine tools in an integrated manner.

[0006] Although the existing remote fault diagnosis system adopts a human-computer interaction design, experienced staff can cope with some difficult faults, but inexperienced staff will encounter obstacles, affecting the normal operation of the equipment. Moreover, the staff has no chance to make mistakes when solving fault problems. Any mistake in any solution will cause irreparable losses to the equipment. Summary of the invention

[0007] In view of the above-mentioned prior art, the technical problem to be solved by the present invention is how to achieve deep human-computer interaction.

[0008] To solve the above problems, the present invention provides a remote fault diagnosis system for a CNC milling machine based on the Internet of Things, comprising a CNC milling machine body and a remote fault diagnosis system body, the remote fault diagnosis system body comprising a data acquisition layer, a data processing layer, a data transmission layer and a remote monitoring and management platform, the data acquisition layer comprising an electrical system monitoring module, a mechanical system monitoring module and an auxiliary system monitoring module, the data processing layer comprising a data filtering module, a data classification and sorting module, a data analysis module and a fault signal extraction module, the data transmission layer comprising a local area network transmission module and a 5G signal communication module, the remote monitoring and management platform comprising a fault diagnosis module, a fault warning module and a maintenance management module, the fault warning module comprising an alarm unit and a fault information prompt unit, and the maintenance management module comprising a regular maintenance reminder unit and a maintenance record unit.

[0009] In the above-mentioned IoT-based CNC milling machine remote fault diagnosis system, a pre-operation simulation module and a fault elimination guidance module are added to help inexperienced workers eliminate faults, which can protect the equipment and effectively improve work efficiency.

[0010] As a further improvement of the present application, the CNC milling machine body includes an operation panel, and a protective box is fixedly connected to one side of the operation panel, and an analog panel is installed inside the protective box. The remote fault diagnosis system body also includes an interactive layer, and the interactive layer is installed on the analog panel. The interactive layer includes a pre-operation simulation module and a fault elimination guidance module. The pre-operation simulation module includes a predetermined key operation template retrieval unit, an actual key operation monitoring unit, an approval unit, a re-operation unit, an actual operation permission unit and an error marking unit. The fault elimination guidance module includes an audio prompt unit and a key operation sequence prompt unit.

[0011] As a further improvement of the present application, the simulation panel has the same structure as the control panel, the simulation panel includes a shell, an LED screen is installed on the top of the shell, and a plurality of buttons are installed on the bottom of the shell, a plurality of embedded seats are installed inside the shell, and one embedded seat corresponds to one button, an installation cavity is opened on the inner wall of the embedded seat, and a light-emitting column is slidably connected to the inside of the installation cavity, the light-emitting column passes through the outside of the installation cavity and is fixedly embedded in the button, a plurality of symmetrically distributed spring wires are fixedly connected between the side walls of the button and the side walls of the embedded seat, the side walls of the light-emitting column located inside the installation cavity are fixedly connected to two symmetrically distributed magnetic blocks, and the inner wall of the installation cavity is fixed A magnetic trigger layer is fixedly connected, a light-transmitting hole is opened in the middle of the magnetic trigger layer, and cavities are opened on the inner walls of the magnetic trigger layer on both sides of the light-transmitting hole, a deformable conductive layer is fixedly connected to the inner wall of the cavity, and magnetic fluid is filled between the deformable conductive layer and the inner wall of the cavity, a fixed power-on layer is fixedly connected to the inner wall of the cavity close to the magnetic block, and one end of the fixed power-on layer and the deformable conductive layer are connected to wires, the wire on the deformable conductive layer is connected to the positive electrode of the electrode, and the wire on the fixed power-on layer is connected to the negative electrode of the electrode, and the circuit formed by the deformable conductive layer and the fixed power-on layer is electrically connected to the actual key operation monitoring unit.

[0012] As a further improvement of the present application, the deformable conductive layer includes an elastic base layer, and the elastic base layer is fixedly connected to a flexible conductive layer on a side wall close to the fixed power-carrying layer.

[0013] As another improvement of the present application, a signal light is also installed on the inner wall of the installation cavity facing the light-transmitting hole, and the signal light is electrically connected to the error marking unit and the key operation sequence prompt unit.

[0014] As another improvement of the present application, the light-emitting column is made of light-guiding material, and the button is made of transparent material.

[0015] In summary, on the basis of the existing fault diagnosis system, a pre-operation simulation module and a fault elimination guidance module are added to provide technical support for inexperienced staff, effectively improve the efficiency and accuracy of fault solving, and enable staff to simulate operations in advance by adding a simulation panel, and help staff to make timely modifications and adjustments by monitoring errors in the simulation process. In the process of simulation, it can help inexperienced staff to quickly become familiar with the operating procedures, effectively reduce the error rate in actual operation, and thus effectively protect the equipment from damage. In addition, the pre-simulation can also encourage inexperienced staff to learn independently, which plays a positive role in promoting both man and machine, thereby effectively improving the depth of man-machine interaction. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a module schematic diagram of the first implementation mode of this application; Figure 2 This is a schematic diagram of the interaction layer module of the second implementation mode of this application; Figure 3 A three-dimensional diagram of a CNC milling machine according to a second embodiment of the present application; Figure 4 This is a three-dimensional diagram of a simulation panel according to a second embodiment of the present application; Figure 5 This is a side cross-sectional view of a key before being pressed according to the second embodiment of the present application; Figure 6 This is a side cross-sectional view of a button after being pressed according to the second embodiment of the present application; Figure 7 This is a front cross-sectional view of the magnetic trigger layer before it is turned on in the second embodiment of the present application; Figure 8 This is a front cross-sectional view of the magnetic trigger layer after being turned on in the second embodiment of the present application; Fig. 9 This is a front cross-sectional view of the deformable conductive layer of the second embodiment of the present application.

[0017] Description of the numbers in the figure: 1 CNC milling machine body, 2 control panel, 3 protection box, 4 analog panel, 401 shell, 402 LED screen, 403 button, 5 embedded seat, 501 installation cavity, 6 light-emitting column, 7 spring wire, 8 magnetic block, 9 magnetic trigger layer, 901 light-transmitting hole, 902 cavity, 10 deformable conductive layer, 1001 elastic base layer, 1002 flexible conductive layer, 11 fixed power-on layer, 12 magnetic fluid, 13 indicator light. DETAILED DESCRIPTION

[0018] Two implementation modes of the present application are described in detail below with reference to the accompanying drawings.

[0019] The first implementation method: Figure 1 As shown, it includes a CNC milling machine body 1 and a remote fault diagnosis system body. The remote fault diagnosis system body includes a data acquisition layer, a data processing layer, a data transmission layer and a remote monitoring and management platform. The data acquisition layer includes an electrical system monitoring module, a mechanical system monitoring module and an auxiliary system monitoring module. The electrical system monitoring module, the mechanical system monitoring module and the auxiliary system monitoring module rely on various sensors to monitor the electrical, mechanical, auxiliary equipment and other parts of the CNC milling machine, so as to detect faults in time. The data processing layer includes a data filtering module, a data classification and sorting module, a data analysis module and a fault signal extraction module. The data transmission layer includes a local area network transmission module and a 5G signal communication module. The remote monitoring and management platform includes a fault diagnosis module, a fault warning module and a maintenance management module. The fault warning module includes an alarm unit and a fault information prompt unit. The maintenance management module includes a regular maintenance reminder unit and a maintenance record unit.

[0020] The second implementation method: Figure 2 , 3As shown, the CNC milling machine body 1 includes a control panel 2, and a protective box 3 is fixedly connected to one side of the control panel 2, and a simulation panel 4 is installed inside the protective box 3. The remote fault diagnosis system body also includes an interactive layer, and the interactive layer is installed on the simulation panel 4. The interactive layer includes a pre-operation simulation module and a fault elimination guidance module. The pre-operation simulation module includes a predetermined key operation template retrieval unit, an actual key operation monitoring unit, an approval unit, a re-operation unit, an actual operation permission unit and an error marking unit. The fault elimination guidance module includes an audio prompt unit and a key operation sequence prompt unit. When eliminating the fault, if you encounter a problem that is difficult to solve, you can seek help through the fault elimination guidance module. The audio prompt unit plays a video of specific operation procedures and precautions through the LED screen 402 to help inexperienced staff to quickly and accurately eliminate the fault. At the same time, the key operation sequence prompt unit also lights up the indicator light 13, so that the keys 403 are lit in sequence according to the operation sequence when the fault is eliminated. This can effectively help the staff to be familiar with the operation process in advance. Before the staff actually operates, First, a drill is conducted through the pre-operation simulation module. During the drill, the predetermined key operation template retrieval unit first retrieves the corresponding operation process from the database according to the specific type of fault. Then the actual key operation monitoring unit monitors the pressing of the key. The approval unit compares the signal monitored by the actual key operation monitoring unit with the signal of the predetermined key operation module retrieval unit. If the key 403 actually operated is consistent with the preset virtual key 403, it means that the operation during the drill is correct. If the key 403 actually operated is inconsistent with the preset virtual key 403, it means that an operation error occurred during the drill. Then the re-operation unit restarts the program to let the staff re-rehearse the operation until no error occurs during the drill. The actual operation permission unit monitors the number of times no operation error occurs during the drill. When it is monitored that the staff has performed the operation without error for three consecutive times, the staff is allowed to operate the machine formally. In addition, the error marking unit marks the key 403 that makes repeated mistakes, reminding the staff to operate the specific key 403 operation process here, effectively improving the accuracy of the operation. Figure 4 , 5As shown, the simulation panel 4 has the same structure as the control panel 2. The simulation panel 4 includes a shell 401. An LED screen 402 is installed on the top of the shell 401, and a plurality of buttons 403 are installed on the bottom of the shell 401. A plurality of embedded seats 5 are installed inside the shell 401, and one embedded seat 5 corresponds to one button 403. An installation cavity 501 is opened on the inner wall of the embedded seat 5, and a light-emitting column 6 is slidably connected inside the installation cavity 501. The light-emitting column 6 is made of light-guiding material, and the button 403 is made of transparent material. The light generated by the indicator light 13 is irradiated on the light-emitting column 6 to make it emit light, so that the button 403 can be marked. In order to increase the light-emitting range and brightness, the button 403 is made of transparent material. The light-emitting column 6 penetrates the outside of the installation cavity 501 and is fixedly embedded in the button 403. A plurality of symmetrically distributed spring wires 7 are fixedly connected between the side wall of the button 403 and the side wall of the embedded seat 5. Two symmetrically distributed magnetic blocks 8 are fixedly connected to the side wall of the light-emitting column 6 located inside the installation cavity 501. Figure 5 , 6 As shown, the inner wall of the installation cavity 501 is fixedly connected with a magnetic trigger layer 9, a light-transmitting hole 901 is opened in the middle of the magnetic trigger layer 9, and a signal light 13 is also installed on the inner wall of the installation cavity 501 facing the light-transmitting hole 901, and the signal light 13 is electrically connected to the error marking unit and the key operation sequence prompting unit, the error marking unit marks the repeated wrong key 403 by flashing the signal light 13, and the key operation sequence prompting unit demonstrates the operation sequence of the key 403 by letting the signal light 13 in a breathing light mode; Figure 7 , 8 and Fig. 9 As shown, the inner walls of the magnetic trigger layer 9 located on both sides of the light-transmitting hole 901 are provided with cavities 902, the inner walls of the cavities 902 are fixedly connected with a deformable conductive layer 10, and the inner walls of the deformable conductive layer 10 and the cavities 902 are filled with a magnetic fluid 12, the deformable conductive layer 10 includes an elastic base layer 1001, and the elastic base layer 1001 is fixedly connected with a flexible conductive layer 1002 near the side wall of the fixed power-carrying layer 11, the flexible conductive layer 1002 plays a conductive role, and the elastic base layer 1001 plays a supporting role of the flexible conductive layer 1002, when the magnetic fluid 12 is subjected to the magnetic attraction of the magnetic block 8, the elastic base layer 1001 drives the flexible conductive layer 1002 to stick to the fixed power-carrying layer 11 under the squeezing force of the magnetic fluid 12, so that the deformable conductive layer 10 and the fixed power-carrying layer 11 form a complete circuit loop, thereby generating a current signal so that the button 403 here can be monitored; Figure 7 , 8As shown, the inner wall of the cavity 902 near the magnetic block 8 is fixedly connected with a fixed power-carrying layer 11, and one end of the fixed power-carrying layer 11 and the deformable conductive layer 10 are both connected with wires, the wire on the deformable conductive layer 10 is connected to the positive electrode of the electrode, and the wire on the fixed power-carrying layer 11 is connected to the negative electrode of the electrode, and the circuit formed by the deformable conductive layer 10 and the fixed power-carrying layer 11 is electrically connected to the actual key operation monitoring unit. In the process of pre-simulated operation, after pressing the button 403, the button 403 drives the magnetic block 8 on the light-emitting column 6 to approach the magnetic trigger layer 9. Recently, when the button 403 is pressed into place, the magnetic block 8 relies on magnetic force to attract the magnetic fluid 12. At this time, the magnetic fluid 12 presses the deformable conductive layer 10 onto the fixed power-on layer 11, so that the deformable conductive layer 10 and the fixed power-on layer 11 are conductive. In this way, the actual button operation monitoring unit can monitor the current signal and send this signal to the approval unit. The approval unit compares this button 403 with the virtual button set by the predetermined button operation template calling unit. If the two can correspond, it indicates that the operation is correct. If the two do not correspond, it indicates that the operation is wrong.

[0021] In summary, on the basis of the existing fault diagnosis system, a pre-operation simulation module and a fault elimination guidance module are added to provide technical support for inexperienced staff, effectively improve the efficiency and accuracy of fault resolution, and enable staff to simulate operations in advance by adding a simulation panel 4, and help staff to make timely modifications and adjustments by monitoring errors in the simulation process. In the process of simulation, it can help inexperienced staff to quickly become familiar with the operating procedures, effectively reduce the error rate in actual operation, and thus effectively protect the equipment from damage. In addition, the pre-simulation can also encourage inexperienced staff to learn independently, which plays a positive role in promoting both man and machine, thereby effectively improving the depth of man-machine interaction.

[0022] In view of current practical needs, the above-mentioned implementation mode adopted in this application is not limited to the scope of protection. Various changes made within the knowledge scope of technical personnel in this field without departing from the concept of this application still fall within the scope of protection of the present invention.

Claims

1. A remote fault diagnosis system for CNC milling machines based on the Internet of Things, characterized by: The invention comprises a CNC milling machine body (1) and a remote fault diagnosis system body, wherein the remote fault diagnosis system body comprises a data acquisition layer, a data processing layer, a data transmission layer and a remote monitoring management platform, wherein the data acquisition layer comprises an electrical system monitoring module, a mechanical system monitoring module and an auxiliary system monitoring module, wherein the data processing layer comprises a data filtering module, a data classification and sorting module, a data analysis module and a fault signal extraction module, wherein the data transmission layer comprises a local area network transmission module and a 5G signal communication module, wherein the remote monitoring management platform comprises a fault diagnosis module, a fault warning module and a maintenance management module, wherein the fault warning module comprises an alarm unit and a fault information prompt unit, and wherein the maintenance management module comprises a regular maintenance reminder unit and a maintenance record unit.

2. According to the Internet of Things-based CNC milling machine remote fault diagnosis system of claim 1, it is characterized by: The CNC milling machine body (1) comprises a control panel (2), and a protective box (3) is fixedly connected to one side of the control panel (2), and a simulation panel (4) is installed inside the protection box (3). The remote fault diagnosis system body also comprises an interaction layer, and the interaction layer is installed on the simulation panel (4). The interaction layer comprises a pre-operation simulation module and a fault elimination guidance module. The pre-operation simulation module comprises a predetermined key operation template retrieval unit, an actual key operation monitoring unit, an approval unit, a re-operation unit, an actual operation permission unit and an error marking unit. The fault elimination guidance module comprises an audio prompt unit and a key operation sequence prompt unit.

3. The remote fault diagnosis system for CNC milling machines based on the Internet of Things according to claim 2 is characterized in that: The simulation panel (4) has the same structure as the control panel (2), the simulation panel (4) comprises a shell (401), an LED screen (402) is installed on the top of the shell (401), and a plurality of buttons (403) are installed on the bottom of the shell (401), a plurality of embedded seats (5) are installed inside the shell (401), and one embedded seat (5) corresponds to one button (403), an inner wall of the embedded seat (5) is provided with an installation cavity (501), and a light-emitting column (6) is slidably connected to the inside of the installation cavity (501), the light-emitting column (6) passes through the outside of the installation cavity (501) and is fixedly embedded in the button (403), a plurality of symmetrically distributed spring wires (7) are fixedly connected between the side wall of the button (403) and the side wall of the embedded seat (5), the side wall of the light-emitting column (6) located inside the installation cavity (501) is fixedly connected with two symmetrically distributed magnetic blocks (8), and the installation cavity (501) is provided with a plurality of symmetrically distributed spring wires (7) and a plurality of symmetrically distributed magnetic blocks (8) are fixedly connected to the side wall of the light-emitting column (6) located inside the installation cavity (501), and the light-emitting column (6) is provided with a plurality of symmetrically distributed spring wires (7) and a plurality of symmetrically distributed spring wires (7) are fixedly connected to the side wall of the light-emitting column (6) located inside the installation cavity (501), and the light-emitting column (6) is provided with a plurality of symmetrically distributed magnetic blocks (8) and a plurality of symmetrically distributed spring wires (7) are fixedly connected to the side wall of the light-emitting column (6) located inside the installation cavity (501). The inner wall of the cavity (501) is fixedly connected to a magnetic trigger layer (9), a light-transmitting hole (901) is provided in the middle of the magnetic trigger layer (9), and cavities (902) are provided on the inner walls of the magnetic trigger layer (9) on both sides of the light-transmitting hole (901), the inner wall of the cavity (902) is fixedly connected to a deformable conductive layer (10), and a magnetic fluid (12) is filled between the deformable conductive layer (10) and the inner wall of the cavity (902), and the cavity (902) A fixed power-carrying layer (11) is fixedly connected to the inner wall near the magnetic block (8), and one end of the fixed power-carrying layer (11) and the deformable conductive layer (10) are both connected to a wire, the wire on the deformable conductive layer (10) is connected to the positive electrode of the electrode, and the wire on the fixed power-carrying layer (11) is connected to the negative electrode of the electrode, and the circuit formed by the deformable conductive layer (10) and the fixed power-carrying layer (11) is electrically connected to the actual key operation monitoring unit.

4. The remote fault diagnosis system for CNC milling machines based on the Internet of Things according to claim 3 is characterized in that: The deformable conductive layer (10) comprises an elastic base layer (1001), and the elastic base layer (1001) is fixedly connected to a flexible conductive layer (1002) near a side wall of the fixed power-carrying layer (11).

5. The remote fault diagnosis system for CNC milling machines based on the Internet of Things according to claim 3 is characterized in that: A signal light (13) is also installed on the inner wall of the installation cavity (501) facing the light-transmitting hole (901), and the signal light (13) is electrically connected to the error marking unit and the key operation sequence prompt unit.

6. The remote fault diagnosis system for CNC milling machines based on the Internet of Things according to claim 3 is characterized in that: The light-emitting column (6) is made of a light-guiding material, and the button (403) is made of a transparent material.

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