Cutter monitoring system of precision machining equipment

Abstract

The invention discloses a tool monitoring system for precision machining equipment, and the system comprises a sensor module which is used for collecting a tool cutting force signal, a vibration signal, a temperature signal and a main shaft power signal in real time; the data acquisition module is used for acquiring a cutting force signal, a vibration signal, a temperature signal and a main shaft power signal of the cutter in a machining process in real time; and the alarm module receives the alarm instruction of the data analysis module. According to the tool monitoring system of the precision machining equipment, the cutting force sensor, the vibration sensor, the temperature sensor and the main shaft power sensor are arranged, so that the tool can be conveniently detected in all directions, and the problems of tool missing, chip winding and cutting output change are avoided. And by means of the tool service life management module, the use duration and the machining frequency of the tool can be recorded, the service life of the tool can be predicted conveniently, and machining and use of the workpiece are facilitated.

Description

Technical Field

[0001] The present invention relates to the technical field of precision machining, and in particular to a tool monitoring system for precision machining equipment. Background Art

[0002] Precision machining equipment refers to a type of equipment used to process high-precision and difficult workpieces. In order to improve product processing efficiency, it is usually necessary to monitor and manage the tools. However, in the existing technology, precision machining equipment has the following shortcomings: 1. The sensor is single and mostly relies on current or vibration signals to detect one-dimensional data, which cannot fully reflect the tool status; 2. Delayed manual intervention requires stopping the machine for manual inspection or relying on experience, resulting in production interruptions and low efficiency. 3. Discrete management: Data on tool procurement, use, and grinding are scattered, and there is a lack of closed-loop management, resulting in low collaboration efficiency.

[0003] Therefore, we propose a tool monitoring system for precision machining equipment to solve the above problems. Summary of the Invention

[0004] The purpose of the present invention is to provide a tool monitoring system for precision machining equipment to solve the problems raised in the above-mentioned background technology, such as the current sensors are single, mostly rely on current or vibration signals to detect one-dimensional data, cannot fully reflect the tool status, manual intervention is delayed, and manual inspection or reliance on experience judgment is required, resulting in production interruption, low efficiency, discrete management, scattered data in the procurement, use, and grinding of tools, lack of closed-loop management, and low collaboration efficiency.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a tool monitoring system for precision machining equipment, comprising: Sensor module, used to collect tool vibration signals and spindle power signals in real time; The data acquisition module is used to collect the vibration signal of the tool and the spindle power signal in real time during the processing, and transmit the collected signals to the data analysis module after pre-processing; The data analysis module has a built-in tool status analysis model based on a machine learning algorithm. It receives signal data from the data acquisition module, extracts and analyzes its features, and compares it with the pre-stored tool normal status data model to determine whether the tool is in normal working condition. If the tool is judged to be worn, damaged or in abnormal working condition, it sends an alarm instruction to the alarm module and transmits the analysis results and real-time data to the storage module. The alarm module, after receiving the alarm instruction from the data analysis module, issues an alarm through the sound and light alarm device; A storage module is used to store the tool's historical working data, the analysis results of the data analysis module, and the tool's normal state data model; Monitoring controller, used to receive and process tool status data and control the operation of each module; The tool life management module is connected to the monitoring controller to record the tool usage time and number of processing times, predict the tool life and trigger replacement prompts.

[0006] Preferably, the vibration sensor in the data acquisition module is an acceleration sensor, which is respectively installed on the tool handle and the machine tool workbench to obtain vibration information of the tool and the machining process, with an accuracy of ±0.01g and a sampling frequency of ≥20kHz; The spindle power sensor uses a Hall current sensor, which is connected in series to the power supply line of the tool motor to collect the motor current signal. It can detect AC current of 0.1A-1000A.

[0007] Preferably, the data acquisition module further includes an NC data acquisition unit, which connects the machine tool and the terminal via a network cable, collects the spindle speed and the number of processed parts, and assists in calculating the tool load and life.

[0008] Preferably, the sound and light alarm device of the alarm module includes a high-brightness flashing alarm light and a high-decibel alarm horn. The alarm light is red and flashes at a specific frequency when an alarm is issued, and the alarm horn emits an intermittent high-decibel alarm sound.

[0009] Preferably, the storage module adopts a combination of cloud storage and local storage, and the local storage adopts a solid state drive (SSD) for real-time storage of recent tool working data and analysis results for quick reading.

[0010] Preferably, it also includes a monitoring display module for displaying the operating status of the tool and the sensor.

[0011] Compared with the existing technology, the present invention has the following advantages: the tool monitoring system of the precision machining equipment, by providing cutting force sensors, vibration sensors, temperature sensors and spindle power sensors, facilitates comprehensive detection of the tool, avoids problems such as empty cutting, chip entanglement and changes in cutting volume, and avoids downtime monitoring. Through the tool life management module, it can record the tool usage time and number of processing times, facilitates the prediction of tool life, and facilitates the processing of workpieces. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 Schematic diagram of the tool monitoring system of the present invention; Figure 2 This is a schematic diagram of the tool processing status of the present invention; Figure 3Schematic diagram of tool wear structure of the present invention. DETAILED DESCRIPTION

[0013] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0014] See also Figure 1-3 The present invention provides a technical solution: a tool monitoring system for precision machining equipment, comprising: Sensor module, used to collect tool vibration signals and spindle power signals in real time; The data acquisition module is used to collect the vibration signal of the tool and the spindle power signal in real time during the processing, and transmit the collected signals to the data analysis module after pre-processing; The data analysis module has a built-in tool status analysis model based on a machine learning algorithm. It receives signal data from the data acquisition module, extracts and analyzes its features, and compares it with the pre-stored tool normal status data model to determine whether the tool is in normal working condition. If the tool is judged to be worn, damaged or in abnormal working condition, it sends an alarm instruction to the alarm module and transmits the analysis results and real-time data to the storage module. The alarm module, after receiving the alarm instruction from the data analysis module, issues an alarm through the sound and light alarm device; A storage module is used to store the tool's historical working data, the analysis results of the data analysis module, and the tool's normal state data model; Monitoring controller, used to receive and process tool status data and control the operation of each module; The tool life management module is connected to the monitoring controller to record the tool usage time and number of processing times, predict the tool life and trigger replacement prompts.

[0015] The spindle power sensor in the data acquisition module uses a Hall current sensor, which is connected in series to the power supply line of the tool motor to collect motor current signals. It can detect AC currents of 0.1A-1000A. The sound and light alarm device of the alarm module includes a high-brightness flashing alarm light and a high-decibel alarm horn. The alarm light is red and flashes at a specific frequency when an alarm is issued. The alarm horn emits an intermittent high-decibel alarm sound for alarm. The data acquisition module also includes an NC data acquisition unit, which connects the machine tool and the terminal through a network cable to collect spindle speed and number of processed parts to assist in calculating tool load and life.

[0016] like Figure 2As shown in the figure, during the spindle rotation process, the tool is processing normally; when the tool is entangled with iron chips, the tool resistance increases, the spindle rotation power increases, the normal processing curve gradually rises, and is transmitted to the alarm module through the data analysis module, and an alarm is generated; when the tool cutting amount increases, the spindle rotation power suddenly increases, the normal processing curve suddenly rises, and is transmitted to the alarm module through the data analysis module, and an alarm is generated; when there is no tool on the spindle, the normal processing curve tends to remain unchanged and changes in a straight line.

[0017] The vibration sensor is an acceleration sensor, which is installed on the tool holder and the machine tool workbench respectively to obtain vibration information of the tool and the machining process. Its accuracy is ±0.01g and the sampling frequency is ≥20kHz.

[0018] like Figure 3 As shown in the figure, when the tool is processing normally, the tool curve is wavy. When the tool wear reaches the upper limit, it is transmitted to the alarm module through the data analysis module and an alarm is issued. When the tool is broken, the tool curve will jump. When the jump amplitude reaches the qualified line, the tool can be replaced.

[0019] The storage module adopts a combination of cloud storage and local storage. The local storage uses a solid-state drive (SSD) to store recent tool working data and analysis results in real time for quick reading, and conveniently stores the tool's processing data, service life and alarm times. It also includes a monitoring display module to display the tool's operating status and sensor operating status, making it easy to display the stored data.

[0020] Working principle: The movement state of the spindle is detected by the sensor module on the spindle, and the data is collected to the acquisition module, and then analyzed by the data analysis module. The analyzed data is processed by the monitoring controller, and then enters the storage module for storage and displayed by the monitoring display module. When there is a problem with the data analyzed by the data analysis module, it is transmitted to the alarm module through the monitoring controller to make the alarm sound. At the same time, the data is transmitted to the storage module for storage and displayed by the monitoring display module to facilitate fault query. The tool life management module is connected to the monitoring controller to facilitate the recording of the tool usage. This is the entire working process of the tool monitoring system of the precision machining equipment. The content not described in detail in this manual belongs to the existing technology known to professional and technical personnel in this field.

[0021] The standard parts used in the present invention can all be purchased from the market, and special-shaped parts can be customized according to the description in the specification and the drawings. The specific connection methods of each part adopt conventional means such as mature bolts, rivets, welding, etc. in the existing technology. The machinery, parts and equipment all adopt conventional models in the existing technology, and the circuit connection adopts the conventional connection method in the existing technology, which will not be described in detail here.

[0022] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A tool monitoring system for precision machining equipment, characterized in that: include: Sensor module, used to collect tool vibration signals and spindle power signals in real time; The data acquisition module is used to collect the vibration signal of the tool and the spindle power signal in real time during the processing, and transmit the collected signals to the data analysis module after pre-processing; The data analysis module has a built-in tool status analysis model based on a machine learning algorithm. It receives signal data from the data acquisition module, extracts and analyzes its features, and compares it with the pre-stored tool normal status data model to determine whether the tool is in normal working condition. If the tool is judged to be worn, damaged or in abnormal working condition, it sends an alarm instruction to the alarm module and transmits the analysis results and real-time data to the storage module. The alarm module, after receiving the alarm instruction from the data analysis module, issues an alarm through the sound and light alarm device; A storage module is used to store the tool's historical working data, the analysis results of the data analysis module, and the tool's normal state data model; Monitoring controller, used to receive and process tool status data and control the operation of each module; The tool life management module is connected to the monitoring controller to record the tool usage time and number of processing times, predict the tool life and trigger replacement prompts.

2. The tool monitoring system for precision machining equipment according to claim 1, characterized in that: The vibration sensor in the data acquisition module is an acceleration sensor, which is installed on the tool handle and the machine tool workbench respectively to obtain the vibration information of the tool and the machining process, with an accuracy of ±0.01g and a sampling frequency of ≥20kHz; The spindle power sensor uses a Hall current sensor, which is connected in series to the power supply line of the tool motor to collect the motor current signal. It can detect AC current of 0.1A-1000A.

3. The tool monitoring system for precision machining equipment according to claim 1, characterized in that: The data acquisition module also includes an NC data acquisition unit, which connects the machine tool and the terminal via a network cable to collect the spindle speed and the number of processed parts, and assists in calculating the tool load and life.

4. The tool monitoring system for precision machining equipment according to claim 1, characterized in that: The sound and light alarm device of the alarm module includes a high-brightness flashing alarm light and a high-decibel alarm horn. The alarm light is red and flashes at a specific frequency when an alarm is issued. The alarm horn emits an intermittent high-decibel alarm sound.

5. The tool monitoring system for precision machining equipment according to claim 1, characterized in that: The storage module adopts a combination of cloud storage and local storage. The local storage adopts a solid state drive (SSD) for real-time storage of recent tool working data and analysis results for fast reading.

6. The tool monitoring system for precision machining equipment according to claim 1, characterized in that: It also includes a monitoring display module for displaying the operating status of the tool and the sensor.

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