Working hour simulation calculation system and method of motion control system

Abstract

The invention discloses a man-hour simulation calculation system of a motion control system, and the system comprises a processing file reading module which is used for reading a processing file to obtain a processing instruction sequence; the parameter reading module is used for reading processing parameters set by a user; the speed look-ahead module is used for generating a speed curve according to the machining instruction sequence and the machining parameters; the interpolation algorithm module is used for calculating and generating an interpolation pulse sequence according to the speed curve and the processing instruction sequence; and the time calculation module is used for converting each interpolation pulse in the interpolation pulse sequence into a corresponding machining time numerical value, and accumulating the machining time numerical values through an accumulator to obtain a total working hour time numerical value of simulation machining. Therefore, the processing time value corresponding to each interpolation pulse in the generated interpolation pulse sequence is calculated, and all the processing time values are accumulated through the accumulator, so that the processing time of the motion control system is accurately estimated.

Description

Technical Field

[0001] The present invention belongs to the technical field of motion control, and particularly relates to a man-hour simulation calculation system and method for a motion control system. Background Art

[0002] In a motion control system, accurately predicting the processing man-hours is crucial for production planning, cost accounting, equipment scheduling, and other aspects. Traditional man-hour prediction methods usually estimate based on empirical formulas or simple processing parameters, with large errors and unable to meet the high-precision production requirements. There is a large deviation between the calculation result and the actual processing time. Summary of the Invention

[0003] In view of this, the present invention provides a man-hour simulation calculation system and method for a motion control system, which can simulate the processing process completely according to the actual processing flow without performing any actions of external actuators, and accurately calculate the processing man-hours.

[0004] In a first aspect, the present invention provides a man-hour simulation calculation system for a motion control system, which includes a processing file reading module: used to read a processing file to obtain a processing instruction sequence; a parameter reading module: used to read processing parameters set by a user; a speed look-ahead module: according to the processing instruction sequence and the processing parameters, perform speed planning on a processing trajectory to generate a speed curve; an interpolation algorithm module: according to the speed curve and the processing instruction sequence, calculate and generate an interpolation pulse sequence; a time calculation module: convert each interpolation pulse in the interpolation pulse sequence into a corresponding processing time value, and accumulate the processing time values through an accumulator to obtain a total man-hour time value for simulated processing.

[0005] Further, the conversion of each interpolation pulse in the interpolation pulse sequence into a corresponding processing time value includes: calculating the processing time value corresponding to each interpolation pulse according to the pulse frequency or pulse equivalent of the interpolation pulse sequence: (1) Wherein, is the pulse frequency, which refers to the number of pulses emitted per unit time and is determined by the hardware and software parameters of the motion control system, with the unit of pulse / second; is the processing time value corresponding to each interpolation pulse, with the unit of second.

[0006] Further, the accumulation of the processing time values through the accumulator includes: Initialize the total working hours time value of the accumulator , with an initial value of 0, initialize the pulse frequency ; Accumulate the machining time value corresponding to each interpolation pulse into the time accumulator: (2) Among them, is the currently accumulated total working hours time value; is the machining time value corresponding to the current interpolation pulse.

[0007] Furthermore, the time calculation module further includes calculating the time interval value between every two adjacent interpolation pulses according to the speed curve and the machining parameters, and accumulating the time interval value and the machining time value through an accumulator to obtain the total working hours time value of the simulation machining.

[0008] Furthermore, it further includes a control module: used to trigger the machining file reading module, the parameter reading module, the speed preview module, the interpolation algorithm module and the time calculation module in sequence to ensure that each module works according to a predetermined order and logic; the control module is also used to monitor the operating status of each module.

[0009] Furthermore, the machining parameters include, for example, acceleration, jerk, and spindle speed.

[0010] Furthermore, the time calculation module includes a high-precision clock.

[0011] Furthermore, the time calculation module is also used to: compare the total working hours time value of the simulation machining with the total working hours time value of the actual machining, and adjust the pulse frequency or the accumulation algorithm of the accumulator to calibrate the total working hours time value of the simulation machining.

[0012] Furthermore, the speed preview module is specifically used for: Analyze the machining instruction sequence to determine the speed limit conditions of each machining segment; Combine the speed limit conditions with the acceleration parameter and jerk parameter in the machining parameters to calculate the speed curve of each machining segment; The speed curve is output in the form of a time series.

[0013] In a second aspect, the present invention provides a method for simulating and calculating the working hours of a motion control system, which is applied to the working hours simulation and calculation system of a motion control system as described in any one of the above, and includes the following steps: Read a machining file through a machining file reading module to obtain a machining instruction sequence; Read the processing parameters set by the user through the parameter reading module; Through the velocity look-ahead module, perform velocity planning on the machining trajectory according to the machining instruction sequence and the machining parameters to generate a velocity curve; Through the interpolation algorithm module, calculate and generate an interpolation pulse sequence according to the velocity curve and the machining instruction sequence; Through the time calculation module, convert each interpolation pulse in the interpolation pulse sequence into a corresponding machining time value, and accumulate the machining time values through an accumulator to obtain the total machining time value of the simulated machining.

[0014] The present invention provides a working hour simulation calculation system and method for a motion control system. A working hour simulation calculation system for a motion control system includes a machining file reading module: used to read a machining file to obtain a machining instruction sequence; a parameter reading module: used to read the machining parameters set by the user; a velocity look-ahead module: perform velocity planning on the machining trajectory according to the machining instruction sequence and the machining parameters to generate a velocity curve; an interpolation algorithm module: calculate and generate an interpolation pulse sequence according to the velocity curve and the machining instruction sequence; a time calculation module: convert each interpolation pulse in the interpolation pulse sequence into a corresponding machining time value, and accumulate the machining time values through an accumulator to obtain the total machining time value of the simulated machining. Therefore, the present invention can simulate the machining process completely according to the actual machining process without performing any actions of external actuators. By calculating the machining time value corresponding to each interpolation pulse in the generated interpolation pulse sequence, and then accumulating all the machining time values through an accumulator, the machining working hours of the motion control system can be accurately estimated. Brief Description of the Drawings

[0015] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required to be used in the embodiments. It should be understood that the following drawings only show some embodiments of the present invention, and therefore should not be regarded as limiting the scope. For those of ordinary skill in the art, other related drawings can be obtained based on these drawings without creative efforts.

[0016] Figure 1 It is a schematic diagram of the module connection of a working hour simulation calculation system for a motion control system provided by the present invention; Figure 2 It is a method flow chart of a working hour simulation calculation method for a motion control system provided by the present invention.

[0017] The main component symbols are explained as follows: Processing file reading module - 10; Parameter reading module - 20; Velocity look - ahead module - 30; Interpolation algorithm module - 40; Time calculation module - 50; Control module - 60. Detailed implementation mode

[0018] The embodiments of the present invention will be described in detail below. The examples of the embodiments are shown in the drawings, where the same or similar reference numerals represent the same or similar elements or elements with the same or similar functions throughout. The embodiments described below with reference to the drawings are exemplary and are only used to explain the present invention and should not be construed as a limitation of the present invention.

[0019] Embodiment 1 A man - hour simulation calculation system for a motion control system, as Figure 1 shown, which includes a processing file reading module 10: used to read a processing file to obtain a processing instruction sequence; As mentioned above, the processing file reading module 10 reads the processing file by accessing a specified address in the memory of the motion control system. The processing file contains a processing instruction sequence, such as G - code, M - code, etc. These instruction sequences define the processing path, processing actions, and related parameter settings. The processing file reading module 10 parses the processing instruction sequence item by item, extracts key information, such as movement instructions, cutting instructions, etc., and provides basic data for the speed planning of the subsequent velocity look - ahead module 30 and the interpolation calculation of the interpolation algorithm module 40. Specifically, the processing file reading module 10 performs simulation based on the read processing instruction sequence, and thus parses them in sequence to form the processing path, processing actions, and related parameter settings.

[0020] Parameter reading module 20: used to read the processing parameters set by the user; As mentioned above, the parameter reading module 20 reads the processing parameters set by the user from the user interface or the system configuration file, such as acceleration, jerk, spindle speed, etc. The processing parameters are crucial for the speed planning of the processing trajectory. For example, the acceleration and jerk parameters determine the rate of change of speed during the processing, affecting the smoothness and efficiency of the processing. The parameter reading module 20 transfers the processing parameters to the velocity look - ahead module 30 so that the velocity look - ahead module 30 can perform accurate speed planning.

[0021] Velocity look - ahead module 30: According to the processing instruction sequence and the processing parameters, perform speed planning on the processing trajectory to generate a speed curve; As described above, the velocity preview module 30 performs velocity planning for the machining trajectory based on the machining instruction sequence and machining parameters. The velocity preview module 30 first analyzes the machining instruction sequence to determine the velocity limit conditions for each machining segment, such as cutting velocity, feed rate, etc. Then, in combination with machining parameters such as acceleration and jerk parameters, it calculates the velocity curve for each machining segment to ensure a smooth transition of velocity during the machining process and avoid machining errors and equipment failures caused by sudden velocity changes. The velocity curve is output in the form of a time series to provide a velocity reference for the interpolation algorithm module 40.

[0022] Interpolation algorithm module 40: calculates and generates an interpolation pulse sequence according to the velocity curve and the machining instruction sequence; As described above, the interpolation algorithm module 40 calculates the interpolation pulse sequence according to the velocity curve and the machining instruction sequence. The interpolation algorithm uses common interpolation methods, such as linear interpolation, circular arc interpolation, etc., and generates an interpolation pulse sequence according to the geometric shape of the machining path and the velocity curve. Each interpolation pulse corresponds to a tiny machining displacement. By accumulating the interpolation pulses, the continuous movement of the machining path is simulated, that is, the interpolation action in the actual machining process is simulated. The interpolation algorithm module 40 transmits the interpolation pulses to the time calculation module 50 for calculating the machining time.

[0023] Time calculation module 50: converts each interpolation pulse in the interpolation pulse sequence into a corresponding machining time value, and accumulates the machining time values through an accumulator to obtain the total machining time value of the simulated machining.

[0024] As described above, after receiving the interpolation pulses, the time calculation module 50 converts them into time values. The specific method is to calculate the machining time value corresponding to each interpolation pulse according to the frequency of the interpolation pulses and the pulse equivalent. Then, all the machining time values are accumulated through the accumulator to obtain the total machining time value of the machining process. It should be noted that during this process, the time calculation module 50 discards the action of sending pulses and the driving process of external mechanisms, and only focuses on the accumulation of machining time values. Finally, when all the machining instruction sequences in the machining file are processed, the time calculation module 50 outputs the accumulated total machining time value, and the error between the total machining time value and the actual machining time value is controlled within the millisecond level.

[0025] Therefore, in this embodiment, by reading the processing file and processing parameters, the simulation is carried out exactly according to the actual processing flow, but the actions of any external actuating mechanism are not executed, and the total processing time, that is, the total working hours time value, can be accurately calculated, with an error only at the millisecond level, greatly improving the accuracy of working hours estimation compared with the traditional method. The time calculation module 50 accumulates only the processing time related to the interpolation pulses by discarding the pulse sending process and the external mechanism driving process, reducing unnecessary calculation and execution links and improving the efficiency of simulation calculation. This embodiment is applicable to various motion control system devices and processing technologies, can flexibly perform working hours simulation calculation according to different processing files and processing parameters set by users, has wide applicability, can provide accurate working hours estimation for motion control system enterprises, optimize production plan arrangements, and improve production efficiency and economic benefits.

[0026] In this embodiment, the conversion of each interpolation pulse in the interpolation pulse sequence into a corresponding processing time value includes: Calculating the processing time value corresponding to each interpolation pulse according to the pulse frequency or pulse equivalent of the interpolation pulse sequence: (1) Wherein, is the pulse frequency, which refers to the number of pulses sent per unit time and is determined by the hardware and software parameters of the motion control system, with the unit of pulse / second; is the processing time value corresponding to each interpolation pulse, with the unit of second.

[0027] As described above, the processing time value corresponding to each interpolation pulse ( ) can be calculated from the pulse frequency: For example, if the pulse frequency set by the numerical control system is 10000 pulses / second, the processing time value corresponding to each interpolation pulse is: (3) In the motion control system, the interpolation pulse is the basic signal for controlling the movement of the machine tool, and each interpolation pulse corresponds to a tiny displacement (pulse equivalent) of the machine tool. The pulse equivalent is the smallest displacement unit in the numerical control system and is usually determined by the resolution of the machine tool. For example, when the pulse equivalent is 0.001 mm, each pulse corresponds to the machine tool moving 0.001 mm, and each pulse frequency corresponds to a pulse equivalent.

[0028] In this embodiment, the accumulation of the processing time values by the accumulator includes: Initializing the total working hours time value of the accumulator , with the initial value of 0, and initializing the pulse frequency ; Accumulate the machining time value corresponding to each interpolation pulse into a time accumulator: (2) Wherein, is the current cumulative total working hours time value; is the machining time value corresponding to the current interpolation pulse.

[0029] It is worth further explaining that, in this embodiment, It is also possible to accumulate the time interval values between every two adjacent interpolation pulses to generate a more accurate total working hours time value.

[0030] In this embodiment, the time calculation module 50 further includes calculating the time interval value between every two adjacent interpolation pulses according to the speed curve and the machining parameters, and accumulating the time interval value and the machining time value through an accumulator to obtain the total working hours time value of the simulated machining.

[0031] As described above, in actual machining, there may be an interval time between every two adjacent interpolation pulses (such as the acceleration and deceleration stages). The time calculation module 50 needs to calculate the time interval value according to the speed curve and the machining parameters (acceleration parameter) set by the user, and accumulate multiple time interval values into the total working hours time value. For example, in the acceleration or deceleration stage, the pulse frequency gradually increases or decreases, and the time calculation module 50 needs to calculate the time interval value between every two interpolation pulses according to the speed curve and the acceleration parameter to reduce errors.

[0032] Therefore, the time calculation module 50 accurately calculates the machining time value of each interpolation pulse according to the pulse frequency or pulse equivalent, and accumulates all the machining time values. At the same time, it calculates and accumulates the corresponding time interval value according to the speed change between every two adjacent interpolation pulses to ensure the accuracy of the accumulation of the total working hours time value.

[0033] In this embodiment, a control module 60 is further included: used to sequentially trigger the machining file reading module 10, the parameter reading module 20, the speed preview module 30, the interpolation algorithm module 40, and the time calculation module 50 to ensure that each module works according to a predetermined order and logic; the control module 60 is also used to monitor the running states of each module.

[0034] As described above, in order to ensure that the processing file reading module 10, the parameter reading module 20, the velocity preview module 30, the interpolation algorithm module 40, and the time calculation module 50 work in a predetermined order and logic, the man-hour simulation calculation system of the motion control system further includes a control module 60. Specifically, the control module 60 has arithmetic processing devices such as a CPU (Central Processing Unit). In addition, the control module 60 also has auxiliary storage devices such as an HDD (Hard Disk Drive) that stores various control programs such as application software or an operating system, and a main storage device such as a RAM (Random Access Memory) that stores data temporarily required when the arithmetic processing device executes a program.

[0035] Specifically, the control module 60 controls the processing file reading module 10 to read a processing file and obtain a processing instruction sequence; the processing file can be stored in an external storage device or in the auxiliary storage device, and the parameter reading module 20 reads the processing parameters set by the user. Subsequently, the control module 60 controls the parameter reading module 20 to read the processing parameters set by the user. The control module 60 then controls the velocity preview module 30 to generate a velocity curve according to the processing instruction sequence and the processing parameters. Next, the control module 60 controls the interpolation algorithm module 40 to calculate and generate an interpolation pulse sequence according to the velocity curve and the processing instruction sequence. Finally, the control module 60 controls the time calculation module 50 to convert each interpolation pulse in the interpolation pulse sequence into a corresponding processing time value, and accumulates the processing time values through an accumulator to obtain the total man-hour time value of the simulated processing.

[0036] In this embodiment, the processing parameters include, for example, acceleration, jerk, and spindle speed.

[0037] In this embodiment, the time calculation module 50 includes a high-precision clock.

[0038] As described above, the time calculation module 50 includes a high-precision clock (such as a hardware clock or a software timer), and the resolution of the high-precision clock is usually at the microsecond level or higher, which can meet the requirements of millisecond-level errors. The high-precision clock of the time calculation module 50 increases the accuracy of the accumulator in accumulating the processing time value and the time interval value, can effectively reduce errors, and ensure the accuracy of time calculation.

[0039] In this embodiment, the time calculation module 50 is further configured to: compare the total man-hour time value of the simulated processing with the total man-hour time value of the actual processing, and adjust the pulse frequency or the accumulation algorithm of the accumulator to calibrate the total man-hour time value of the simulated processing.

[0040] As described above, during the simulated machining process, the time calculation module 50 periodically calibrates the total working hours value. Specifically, the accuracy of the pulse frequency directly affects the machining time value of each interpolation pulse. If there is an error in the pulse frequency, it will cause a deviation in the calculation of the machining time value. Therefore, it is necessary to ensure high-precision measurement or setting of the pulse frequency. In addition, by comparing with the total working hours value of the actual machining, the pulse frequency or the accumulation algorithm of the accumulator can be adjusted to ensure that the error of the final output machining working hours is controlled within the millisecond level. Through the above methods, the time calculation module 50 can accurately convert the interpolation pulses into corresponding machining time values, accumulate the machining time values, and finally output a high-precision total machining working hours value, with the error from the total working hours value of the actual machining controlled within the millisecond level.

[0041] In this embodiment, the velocity look-ahead module 30 is specifically configured to: Analyze the machining instruction sequence to determine the speed limit conditions for each machining segment; Combine the speed limit conditions with the acceleration parameter and jerk parameter in the machining parameters to calculate the speed curve for each machining segment; The speed curve is output in the form of a time series.

[0042] Embodiment 2 A method for simulating and calculating the working hours of a motion control system, as Figure 2 shown, which is applied to the working hours simulation and calculation system of the motion control system described in any one of Embodiment 1, and includes the following steps: S1 Read the machining file through the machining file reading module 10 to obtain the machining instruction sequence; S2 Read the machining parameters set by the user through the parameter reading module 20; S3 Through the velocity look-ahead module 30, perform speed planning on the machining trajectory according to the machining instruction sequence and the machining parameters to generate a speed curve; S4 Calculate and generate an interpolation pulse sequence through the interpolation algorithm module 40 according to the speed curve and the machining instruction sequence; S5 Through the time calculation module 50, convert each interpolation pulse in the interpolation pulse sequence into a corresponding machining time value, and accumulate the machining time values through an accumulator to obtain the total working hours value of the simulated machining.

[0043] As described above, the working-hour simulation calculation method of the motion control system of this embodiment reads the processing file and processing parameters, and performs simulation completely according to the actual processing process, but does not execute the actions of any external execution mechanisms, and can accurately calculate the total processing working hours, that is, the total working-hour time value, with an error only at the millisecond level, greatly improving the accuracy of working-hour estimation compared with the traditional method. The time calculation module 50 accumulates the processing time related to the interpolation pulses only by discarding the pulse-sending process and the external mechanism driving process, reducing unnecessary calculation and execution links, and improving the efficiency of simulation calculation. This embodiment is applicable to various motion control system devices and processing technologies, can flexibly perform working-hour simulation calculation according to different processing files and processing parameters set by users, has wide applicability, can provide accurate working-hour estimation for motion control system enterprises, optimize production plan arrangements, and improve production efficiency and economic benefits.

[0044] In all the examples shown and described here, any specific value should be construed as merely exemplary, not as a limitation. Therefore, other examples of the exemplary embodiments may have different values.

[0045] It should be noted that like reference numerals and letters denote like items in the following figures. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0046] The above-described embodiments merely represent several implementation manners of the present invention. The description thereof is relatively specific and detailed, but should not be construed as a limitation on the scope of the present invention. It should be pointed out that for those of ordinary skill in the art, without departing from the concept of the present invention, several modifications and improvements can still be made, and these all belong to the protection scope of the present invention.

Claims

1. A man-hour simulation calculation system for a motion control system, characterized in that It includes a processing file reading module: which is used to read the processing file to obtain a processing instruction sequence; a parameter reading module: which is used to read the processing parameters set by the user; a speed look-ahead module: which performs speed planning on the processing trajectory according to the processing instruction sequence and the processing parameters to generate a speed curve; an interpolation algorithm module: which calculates and generates an interpolation pulse sequence according to the speed curve and the processing instruction sequence; a time calculation module: which converts each interpolation pulse in the interpolation pulse sequence into a corresponding processing time value, and accumulates the processing time values through an accumulator to obtain the total working hour time value of the simulated processing.

2. The man-hour simulation calculation system of the motion control system according to claim 1, characterized in that The conversion of each interpolation pulse in the interpolation pulse sequence into a corresponding processing time value includes: calculating the processing time value corresponding to each interpolation pulse according to the pulse frequency or pulse equivalent of the interpolation pulse sequence: （1） Among them, is the pulse frequency, which refers to the number of pulses emitted per unit time and is determined by the hardware and software parameters of the motion control system, with the unit of pulse / second; is the machining time value corresponding to each interpolation pulse, with the unit of second.

3. The man-hour simulation calculation system of the motion control system according to claim 2, characterized in that The accumulation of the processing time values through the accumulator includes: Initialize the total working hours value of the accumulator , with an initial value of 0, and initialize the pulse frequency ; accumulating the processing time value corresponding to each interpolation pulse into a time accumulator: （2） Among them, is the current cumulative total working hour time value; is the machining time value corresponding to the current interpolation pulse.

4. The man-hour simulation calculation system of the motion control system according to claim 2, characterized in that, The time calculation module further includes calculating the time interval value between every two adjacent interpolation pulses according to the speed curve and the processing parameters, and accumulating the time interval value and the processing time value through the accumulator to obtain the total working hour time value of the simulated processing.

5. The man-hour simulation calculation system of the motion control system according to claim 1, wherein It further includes a control module: which is used to trigger the processing file reading module, the parameter reading module, the speed look-ahead module, the interpolation algorithm module and the time calculation module in sequence to ensure that each module works according to a predetermined order and logic; the control module is also used to monitor the running states of each module.

6. The man-hour simulation calculation system of the motion control system according to claim 1, characterized in that The processing parameters include, for example, acceleration, jerk, and spindle speed.

7. The man-hour simulation calculation system of the motion control system according to claim 1, characterized in that The time calculation module includes a high-precision clock.

8. The man-hour simulation calculation system of the motion control system according to claim 3, characterized in that, The time calculation module is further used to: compare the total working hour time value of the simulated processing with the total working hour time value of the actual processing, and adjust the pulse frequency or the accumulation algorithm of the accumulator to calibrate the total working hour time value of the simulated processing.

9. The man-hour simulation calculation system of the motion control system according to claim 1, characterized in that, The speed look-ahead module is specifically used for: analyzing the processing instruction sequence to determine the speed limit conditions of each processing segment; combining the speed limit conditions with the acceleration parameter and jerk parameter in the processing parameters to calculate the speed curve of each processing segment; The speed curve is output in the form of a time series.

10. A method for simulating and calculating the man-hour of a motion control system, characterized in that, A working hour simulation calculation system applied to a motion control system according to any one of claims 1-9 includes the following steps: reading a processing file through the processing file reading module to obtain a processing instruction sequence; reading the processing parameters set by the user through the parameter reading module; performing speed planning on the processing trajectory according to the processing instruction sequence and the processing parameters through the speed look-ahead module to generate a speed curve; calculating and generating an interpolation pulse sequence according to the speed curve and the processing instruction sequence through the interpolation algorithm module; converting each interpolation pulse in the interpolation pulse sequence into a corresponding processing time value through the time calculation module, and accumulating the processing time values through an accumulator to obtain the total working hour time value of the simulated processing.

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