Software-based tool state monitoring method and device, medium and terminal

Abstract

The invention discloses a tool state monitoring method and device based on software, a medium and a terminal, relates to the technical field of safety machining of numerical control machine tools, and mainly aims to improve the problem that in an existing tool monitoring method, a link of data acquisition by a sensor is added; the condition of inaccurate basic data caused by sensor errors easily occurs, and the monitoring result of the machining state of the cutter is reduced. Comprising the steps that firstly, an NC program transmits a target process number to a PLC program, instructs the PLC program to collect multiple time sequence point real-time driving data corresponding to the target process number, obtains corresponding time sequence point reference driving data according to the target process number and time sequence points, and meanwhile transmits target monitoring process parameters corresponding to a target monitoring process to an embedded program; and finally, the embedded program determines the machining state of the current tool in the target monitoring procedure according to the real-time driving data of the multiple time sequence points and the corresponding time sequence point reference driving data on the basis of the target monitoring process parameters.

Description

Technical Field

[0001] The present application relates to the technical field of safe machining of CNC machine tools, and in particular to a tool status monitoring method and device, medium, and terminal based on software implementation. Background Art

[0002] During the CNC machine tool processing, the tool's processing status directly affects the machine's processing safety, processing accuracy, and workpiece processing quality. Therefore, it is necessary to monitor the tool's processing status.

[0003] Currently, most monitoring of tool processing status requires adding sensors to CNC machine tools in advance, and then collecting specified data through the sensors. For example, the servo axis motor current during tool processing is collected through a current sensor, or the vibration data during tool processing is collected through a vibration sensor.

[0004] However, due to the addition of the sensor data collection link, it is very easy for the basic data to be inaccurate due to sensor errors, which in turn leads to a decline in the tool processing status monitoring results. Summary of the Invention

[0005] In view of this, the present application provides a software-based tool status monitoring method and device, medium, and terminal. The main purpose is to improve the existing tool monitoring method, which is prone to inaccurate basic data due to sensor errors due to the addition of sensors to collect data, thereby leading to a decline in tool processing status monitoring results.

[0006] According to one aspect of the present application, a software-based tool status monitoring method is provided, which is applied to an NC program in a CNC machine tool system, comprising:

[0007] During the process of machining the target workpiece, when the target monitoring process is executed, the target process number corresponding to the target monitoring process is transmitted to the PLC program (data center software) in the CNC machine tool system, and the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program in the CNC machine tool system;

[0008] Instructing the PLC program to periodically collect real-time driving data of a plurality of timing points corresponding to the target process number at preset time intervals, obtain corresponding timing point reference driving data according to the target process number and the timing point, and transmit the plurality of real-time driving data of the timing points and the corresponding timing point reference driving data to the embedded program;

[0009] The embedded program is instructed to determine the machining state of the current tool in the target monitoring process based on the target monitoring process parameters and the real-time driving data of the plurality of sequential points and the corresponding benchmark driving data of the sequential points.

[0010] Preferably, the target monitoring process parameters include a target preset wear coefficient and a target preset wear life, a target preset fracture coefficient and a target preset fracture life, a target preset missing coefficient and a target preset missing life. Based on the target monitoring process parameters, according to the real-time driving data of the plurality of time sequence points and the corresponding reference driving data of the time sequence points, determining the machining state of the current tool in the target monitoring process includes:

[0011] Calculate the ratio between the real-time driving data at each time point and the reference driving data at the corresponding time point in a time sequence order, and use each ratio as a target ratio;

[0012] If the target ratio is greater than the target preset fracture coefficient, the time sequence point corresponding to the target ratio is marked as a fracture time sequence point;

[0013] If the target ratio is less than the target preset fracture coefficient and greater than the target preset wear coefficient, the time sequence point corresponding to the target ratio is marked as a wear time sequence point;

[0014] If the target ratio is less than the target preset wear coefficient and greater than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a normal timing point;

[0015] If the target ratio is less than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a missing timing point;

[0016] Monitor the number of broken timing points, the number of worn timing points, and the number of missing timing points respectively;

[0017] If the number of the fracture timing points reaches the target preset fracture life first, then determining that the machining state of the current tool in the target monitoring process is a fracture state;

[0018] If the number of the wear time sequence points reaches the target preset wear life first, then determining that the current machining state of the tool in the target monitoring process is a wear state;

[0019] If the number of the missing timing points reaches the target preset missing life first, it is determined that the machining state of the current tool in the target monitoring process is a missing state.

[0020] Preferably, after determining the machining state of the current tool in the target monitoring process based on the target monitoring process parameters and the real-time driving data of the plurality of sequential points and the corresponding benchmark driving data of the sequential points, the method further comprises:

[0021] If the processing state is a broken state, a worn state, or a missing state, a processing stop instruction is triggered, and an alarm message corresponding to the broken state, the worn state, or the missing state is output.

[0022] Preferably, during the process of machining the target workpiece, when the target monitoring process is executed, before transmitting the target process number corresponding to the target monitoring process to the PLC program in the CNC machine tool system and transmitting the target monitoring process parameters corresponding to the target monitoring process to the embedded program in the CNC machine tool system, the method further includes:

[0023] When the current tool reaches an optimal state, processing the reference workpiece using the current tool;

[0024] During the machining of the reference workpiece, the process number corresponding to each expected monitoring process is transmitted to the PLC program in the CNC machine tool system;

[0025] Instructing the PLC program to periodically collect and store multiple sequential point reference drive data corresponding to each process number according to the preset time interval;

[0026] When it is monitored that the processing of the reference workpiece is completed, a reference drive data sampling end instruction is triggered to end the reference drive data sampling thread.

[0027] Preferably, the CNC machine tool system includes an NC program, a PLC program and an embedded program;

[0028] The NC program is used to issue instructions to the PLC program and the embedded program, so that the PLC program and the embedded program execute tasks according to the instructions;

[0029] The PLC program is used to collect real-time drive data and benchmark drive data at sequential points;

[0030] The embedded program is used to determine the machining status of the tool.

[0031] Preferably, the embedded program further includes a monitoring interface for manual interaction to receive a reference drive data sampling start instruction and a reference drive data sampling end instruction, output a tool processing status, and output alarm information.

[0032] Preferably, the target preset loss coefficient is smaller than the target preset wear coefficient and smaller than the target preset fracture coefficient.

[0033] According to another aspect of the present application, a tool condition monitoring device based on software is provided, comprising:

[0034] An information transmission module is used to transmit, when a target monitoring process is executed during the processing of a target workpiece, a target process number corresponding to the target monitoring process to a PLC program in a CNC machine tool system, and to transmit target monitoring process parameters corresponding to the target monitoring process to an embedded program in the CNC machine tool system;

[0035] a real-time drive data acquisition module, configured to instruct the PLC program to periodically acquire real-time drive data of a plurality of sequential points corresponding to the target process number at preset time intervals, obtain corresponding sequential point reference drive data based on the target process number and the sequential point, and transmit the plurality of real-time drive data of the sequential points and the corresponding sequential point reference drive data to the embedded program;

[0036] The tool processing state determination module is used to instruct the embedded program to determine the processing state of the current tool in the target monitoring process based on the target monitoring process parameters, the real-time driving data of multiple timing points and the corresponding timing point reference driving data.

[0037] Preferably, the target monitoring process parameters include a target preset wear coefficient and a target preset wear life, a target preset fracture coefficient and a target preset fracture life, a target preset missing coefficient and a target preset missing life, and the tool processing state determination module is used to:

[0038] Calculate the ratio between the real-time driving data at each time point and the reference driving data at the corresponding time point in a time sequence order, and use each ratio as a target ratio;

[0039] If the target ratio is greater than the target preset fracture coefficient, the time sequence point corresponding to the target ratio is marked as a fracture time sequence point;

[0040] If the target ratio is less than the target preset fracture coefficient and greater than the target preset wear coefficient, the time sequence point corresponding to the target ratio is marked as a wear time sequence point;

[0041] If the target ratio is less than the target preset wear coefficient and greater than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a normal timing point;

[0042] If the target ratio is less than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a missing timing point;

[0043] Monitor the number of broken timing points, the number of worn timing points, and the number of missing timing points respectively;

[0044] If the number of the fracture timing points reaches the target preset fracture life first, then determining that the machining state of the current tool in the target monitoring process is a fracture state;

[0045] If the number of the wear time sequence points reaches the target preset wear life first, then determining that the current machining state of the tool in the target monitoring process is a wear state;

[0046] If the number of the missing timing points reaches the target preset missing life first, it is determined that the machining state of the current tool in the target monitoring process is a missing state.

[0047] Preferably, after the tool processing state determination module, the device further includes an alarm module for:

[0048] If the processing state is a broken state, a worn state, or a missing state, a processing stop instruction is triggered, and an alarm message corresponding to the broken state, the worn state, or the missing state is output.

[0049] Preferably, before the information transmission module, the device further includes a reference drive data acquisition module for:

[0050] When the current tool reaches an optimal state, processing the reference workpiece using the current tool;

[0051] During the machining of the reference workpiece, the process number corresponding to each expected monitoring process is transmitted to the PLC program in the CNC machine tool system;

[0052] Instructing the PLC program to periodically collect and store multiple sequential point reference drive data corresponding to each process number according to the preset time interval;

[0053] When it is monitored that the processing of the reference workpiece is completed, a reference drive data sampling end instruction is triggered to end the reference drive data sampling thread.

[0054] Preferably, the CNC machine tool system includes an NC program, a PLC program and an embedded program;

[0055] The NC program is used to issue instructions to the PLC program and the embedded program, so that the PLC program and the embedded program execute tasks according to the instructions;

[0056] The PLC program is used to collect real-time drive data and benchmark drive data at sequential points;

[0057] The embedded program is used to determine the machining status of the tool.

[0058] Preferably, the embedded program further includes a monitoring interface for manual interaction to receive a reference drive data sampling start instruction and a reference drive data sampling end instruction, output a tool processing status, and output alarm information.

[0059] Preferably, the target preset loss coefficient is smaller than the target preset wear coefficient and smaller than the target preset fracture coefficient.

[0060] According to another aspect of the present application, a storage medium is provided, in which at least one executable instruction is stored. The executable instruction enables a processor to execute operations corresponding to the tool condition monitoring method based on software implementation as described above.

[0061] According to another aspect of the present application, there is provided a terminal, comprising: a processor, a memory, a communication interface, and a communication bus, wherein the processor, the memory, and the communication interface communicate with each other via the communication bus;

[0062] The memory is used to store at least one executable instruction, and the executable instruction enables the processor to execute operations corresponding to the above-mentioned tool condition monitoring method based on software implementation.

[0063] By means of the above technical solution, the technical solution provided by the embodiment of the present application has at least the following advantages:

[0064] The present application provides a tool state monitoring method and device, medium, and terminal based on software implementation. First, during the process of processing a target workpiece, when the target monitoring process is executed, the target process number corresponding to the target monitoring process is transmitted to the PLC program (data center software) in the CNC machine tool system, and the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program in the CNC machine tool system; secondly, the PLC program is instructed to periodically collect the real-time driving data of multiple timing points corresponding to the target process number according to a preset time interval, and obtain the corresponding timing point reference driving data according to the target process number and the timing point, and transmit the multiple real-time driving data of the timing points and the corresponding timing point reference driving data to the embedded program; finally, the embedded program is instructed to determine the processing state of the current tool in the target monitoring process based on the target monitoring process parameters and the multiple real-time driving data of the timing points and the corresponding timing point reference driving data. Compared with the prior art, the embodiment of the present application, through the interaction between the NC program, the PLC program and the embedded program, first transmits the target process number to the PLC program by the NC program to instruct the PLC program to collect real-time driving data of multiple timing points corresponding to the target process number, and obtains corresponding timing point reference driving data based on the target process number and the timing point. At the same time, the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program. Finally, the embedded program determines the current processing status of the tool in the target monitoring process based on the target monitoring process parameters, the real-time driving data of the multiple timing points and the corresponding timing point reference driving data. The monitoring of the tool status is realized based on software, without the need to collect data through sensors, avoiding the problem of inaccurate basic data caused by sensor errors, ensuring the accuracy of the basic data, and thus improving the accuracy of the tool processing status monitoring results.

[0065] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present application. The same reference symbols are used throughout the drawings to represent the same components. In the drawings:

[0067] Figure 1 A flowchart of a tool status monitoring method based on software implementation provided in an embodiment of the present application is shown;

[0068] Figure 2 A flowchart of another tool status monitoring method based on software implementation provided in an embodiment of the present application is shown;

[0069] Figure 3 A block diagram of a tool status monitoring device implemented based on software according to an embodiment of the present application is shown;

[0070] Figure 4 A schematic diagram of the structure of a terminal provided in an embodiment of the present application is shown. DETAILED DESCRIPTION

[0071] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art.

[0072] At the same time, it should be understood that for the convenience of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship.

[0073] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the present disclosure, its application, or uses.

[0074] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.

[0075] It should be noted that like reference numerals and letters refer to like items in the following figures, and therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0076] Embodiments of the present application may be applied to a computer system / server that is operable with numerous other general-purpose or special-purpose computing system environments or configurations. Examples of well-known computing systems, environments, and / or configurations suitable for use with the computer system / server include, but are not limited to, personal computer systems, server computer systems, thin clients, thick clients, handheld or laptop devices, microprocessor-based systems, set-top boxes, programmable consumer electronics, network personal computers, minicomputer systems, mainframe computer systems, and distributed cloud computing technology environments including any of the foregoing.

[0077] Computer systems / servers may be described in the general context of computer system-executable instructions, such as program modules, executed by a computer system. Generally, program modules may include routines, programs, objects, components, logic, data structures, and the like, that perform specific tasks or implement specific abstract data types. Computer systems / servers may be implemented in a distributed cloud computing environment where tasks are performed by remote processing devices linked through a communications network. In a distributed cloud computing environment, program modules may be located on local or remote computer system storage media, including storage devices.

[0078] The embodiment of the present application provides a tool status monitoring method based on software implementation, which is applied to the NC program in the CNC machine tool system, such as Figure 1 As shown, the method includes:

[0079] 101. During the process of processing the target workpiece, when the target monitoring process is executed, the target process number corresponding to the target monitoring process is transmitted to the PLC program in the CNC machine tool system, and the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program in the CNC machine tool system.

[0080] Among them, the target monitoring process is used to represent any process in the expected monitoring process, and the expected monitoring process is used to represent the process that requires tool status monitoring. It can be understood that each process in the NC program has a corresponding process number for identifying the process, such as H1=0, H2=0...H20=0, etc.; the target monitoring process parameters are used to represent the monitoring process parameters corresponding to the target monitoring process, including but not limited to the target preset wear coefficient and target preset wear life, the target preset fracture coefficient and target preset fracture life, the target preset missing coefficient and target preset missing life. In the embodiment of the present application, the current execution end is the NC program in the CNC machine tool system.

[0081] It should be noted that the CNC machine tool system includes NC programs, PLC programs and embedded programs; the NC program is used to issue instructions to the PLC program and the embedded program so that the PLC program and the embedded program perform tasks according to the instructions; the PLC program is used to collect real-time drive data of timing points and benchmark drive data of timing points; the embedded program is used to determine the processing status of the tool.

[0082] The interaction between the above three programs is as follows: when the CNC machine tool system is turned on and operates normally, the NC program is started, and the machine tool processes the workpiece according to the instructions of the NC program. During the processing, when the target monitoring process is executed, the timing point reference drive data acquisition instruction and the timing point real-time drive data acquisition instruction are sent to the PLC program to instruct the PLC program to perform the task according to the instructions; at the same time, the processing status determination instruction is sent to the embedded program to instruct the embedded program to perform the processing status determination task based on the target monitoring process parameters, the timing point real-time drive data and the corresponding timing point reference drive data; finally, the continue processing or stop processing instruction is issued according to the processing status. When the CNC machine tool system is powered on and operating normally, the PLC program automatically begins operation, continuously reading the CNC machine tool system's drive data in real time according to timing and logical steps. Upon receiving the NC program's timing point reference drive data acquisition instructions and timing point real-time drive data acquisition instructions, the program periodically collects multiple timing point real-time drive data corresponding to the target process number at preset time intervals, and acquires the corresponding timing point reference drive data based on the target process number and timing point, and transmits the multiple timing point real-time drive data and the corresponding timing point reference drive data to the embedded program. After receiving the processing status determination instruction issued by the NC program, the embedded program performs the processing status determination task based on the target monitoring process parameters, the timing point real-time drive data and the corresponding timing point reference drive data, and feeds the results back to the NC program and PLC program.

[0083] 102. Instruct the PLC program to periodically collect the real-time driving data of multiple timing points corresponding to the target process number according to the preset time interval, and obtain the corresponding timing point benchmark driving data according to the target process number and the timing point, and transmit the real-time driving data of the multiple timing points and the corresponding timing point benchmark driving data to the embedded program.

[0084] Among them, the preset time interval can be set according to the monitoring accuracy, for example, 500ms, etc.; the timing point real-time drive data is used to characterize the real-time drive data at the time of collection, for example, the preset time interval is 500ms, and the timing point real-time drive data is the real-time drive data at the 500ms, the real-time drive data at the 1s, the real-time drive data at the 1500ms, the real-time drive data at the 2s, etc. in the target monitoring process. It should be noted that the timing point benchmark drive data corresponds one-to-one with the timing point real-time drive data, that is, the acquisition period of the two must be the same. In the embodiment of the present application, the PLC program periodically collects multiple timing point real-time drive data corresponding to the target process number according to the preset time interval according to the instruction; at the same time, obtains the benchmark drive data matching the target process number from the benchmark data storage area, and periodically obtains the timing point benchmark drive data corresponding to each timing point from the benchmark drive data according to the above-mentioned preset time interval; finally, the timing point real-time drive data and the corresponding timing point benchmark drive data are transmitted to the embedded program in the form of mapping.

[0085] 103. Instruct the embedded program to determine the machining status of the current tool in the target monitoring process based on the target monitoring process parameters and the real-time driving data of multiple timing points and the corresponding benchmark driving data of the timing points.

[0086] The processing state includes a broken state, a worn state, a missing state, and a normal state. In the embodiment of the present application, an embedded program is used to determine the processing state of the current tool in the target monitoring process. Due to the powerful computing function of the embedded program, the computing efficiency can be effectively improved, thereby ensuring the real-time performance of tool status monitoring.

[0087] Compared with the prior art, the embodiment of the present application, through the interaction between the NC program, the PLC program and the embedded program, first transmits the target process number to the PLC program by the NC program to instruct the PLC program to collect real-time driving data of multiple timing points corresponding to the target process number, and obtains corresponding timing point reference driving data based on the target process number and the timing point. At the same time, the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program. Finally, the embedded program determines the current processing status of the tool in the target monitoring process based on the target monitoring process parameters, the real-time driving data of the multiple timing points and the corresponding timing point reference driving data. The monitoring of the tool status is realized based on software, without the need to collect data through sensors, avoiding the problem of inaccurate basic data caused by sensor errors, ensuring the accuracy of the basic data, and thus improving the accuracy of the tool processing status monitoring results.

[0088] The present application embodiment provides another tool status monitoring method based on software implementation, such as Figure 2 As shown, the method includes:

[0089] 201. Collect multiple sequential point reference drive data generated when the current tool is in the optimal state and processes the reference workpiece.

[0090] Accordingly, step 201 of the embodiment specifically includes: when the current tool reaches the optimal state, using the current tool to process the reference workpiece; in the process of processing the reference workpiece, transmitting the process number corresponding to each expected monitoring process to the PLC program in the CNC machine tool system; instructing the PLC program to periodically collect and store multiple time-series point reference drive data corresponding to each process number according to a preset time interval; when it is monitored that the processing of the reference workpiece is completed, triggering the reference drive data sampling end instruction to end the reference drive data sampling thread.

[0091] Among them, the current tool reaches the optimal state, which is used to characterize the state reached by the tool after running-in, usually the state reached by an unused tool after processing 1 to 2 workpieces; the reference workpiece is used to characterize the workpiece that is identical to the target workpiece.

[0092] Optionally, the embedded program also includes a monitoring interface for manual interaction to receive a reference drive data sampling start instruction and a reference drive data sampling end instruction, output the tool processing status, and output alarm information.

[0093] Based on this, in an embodiment of the present application, the operator can also use the monitoring interface to control the benchmark drive data collection process. Specifically, the operator can trigger the benchmark drive data collection instruction based on the Collection Start button in the monitoring interface. At this time, the monitoring interface will highlight the Collection ON indicator, and the NC program will send the instruction to the PLC program. After receiving the instruction, the PLC program will periodically collect and store multiple timing point benchmark drive data corresponding to each process number according to the preset time interval. Furthermore, after the collection is completed, the operator can press the highlighted Collection ON button to trigger the benchmark drive data sampling end instruction, thereby ending the benchmark drive data sampling thread.

[0094] 202. During the process of processing the target workpiece, when the target monitoring process is executed, the target process number corresponding to the target monitoring process is transmitted to the PLC program in the CNC machine tool system, and the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program in the CNC machine tool system.

[0095] For step 202 of the embodiment, reference may be made to the detailed description of step 101 of the aforementioned embodiment, which will not be repeated here.

[0096] 203. Instruct the PLC program to periodically collect the real-time driving data of multiple timing points corresponding to the target process number according to the preset time interval, and obtain the corresponding timing point benchmark driving data according to the target process number and the timing point, and transmit the real-time driving data of the multiple timing points and the corresponding timing point benchmark driving data to the embedded program.

[0097] For step 203 of the embodiment, reference may be made to the detailed description of step 102 of the aforementioned embodiment, which will not be repeated here.

[0098] 204. Calculate the ratio between the real-time driving data at each time point and the corresponding reference driving data at each time point one by one in a time sequence order.

[0099] In the embodiment of the present application, the ratio between the real-time driving data at each timing point and the reference driving data at the corresponding timing point calculated one by one in the timing order is the ratio corresponding to each timing point.

[0100] 205. According to the ratio, based on the target preset fracture coefficient, the target preset wear coefficient and the target preset missing coefficient in the target monitoring process parameters, the state of each time point is determined.

[0101] Specifically, step 205 of the embodiment specifically includes: calculating the ratio between the real-time driving data of each timing point and the corresponding benchmark driving data of the timing point in chronological order, and taking each ratio as the target ratio one by one; if the target ratio is greater than the target preset fracture coefficient, the timing point corresponding to the target ratio is marked as a fracture timing point; if the target ratio is less than the target preset fracture coefficient and greater than the target preset wear coefficient, the timing point corresponding to the target ratio is marked as a wear timing point; if the target ratio is less than the target preset wear coefficient and greater than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a normal timing point; if the target ratio is less than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a missing timing point.

[0102] Among them, the target preset missing coefficient is less than the target preset wear coefficient and is less than the target preset fracture coefficient.

[0103] For example, the target preset missing coefficient is set to 0.8, the target preset wear coefficient is set to 1.2, and the target preset fracture coefficient is set to 1.5. If the target ratio is greater than 0.8, the timing point corresponding to the target ratio is marked as a fracture timing point; if the target ratio is less than 1.5 and greater than 1.2, the timing point corresponding to the target ratio is marked as a wear timing point; if the target ratio is less than 1.2 and greater than 0.8, the timing point corresponding to the target ratio is marked as a normal timing point; if the target ratio is less than 0.8, the timing point corresponding to the target ratio is marked as a missing timing point. In this way, the status of each timing point is determined.

[0104] 206. Monitor the number of fracture timing points, the number of wear timing points, and the number of missing timing points respectively; if the number of timing points reaches the corresponding target preset life first, the processing state of the target monitoring process is determined to be the corresponding state.

[0105] Specifically, step 206 of the embodiment specifically includes: if the number of fracture timing points reaches the target preset fracture life first, then the processing state of the current tool in the target monitoring process is determined to be a fracture state; if the number of wear timing points reaches the target preset wear life first, then the processing state of the current tool in the target monitoring process is determined to be a wear state; if the number of missing timing points reaches the target preset missing life first, then the processing state of the current tool in the target monitoring process is determined to be a missing state.

[0106] Among them, the target monitoring process parameters also include the target preset wear life, the target preset fracture life, and the target preset missing life. The target preset wear life is used to characterize the maximum number of times the target preset wear coefficient is allowed to be exceeded, that is, when the number of wear timing points of the current tool exceeds the target preset wear life during the processing, it means that the current tool is worn. If the processing continues, the safety risk may increase and the processing accuracy may decrease; similarly, the target preset fracture life is used to characterize the maximum number of times the target preset fracture coefficient is allowed to be exceeded, that is, when the number of fracture timing points of the current tool exceeds the target preset fracture life during the processing, it means that the current tool may have broken; the target preset missing life is used to characterize the maximum number of times the target preset missing coefficient is allowed to be exceeded, that is, when the number of missing timing points of the current tool exceeds the target preset missing life during the processing, it means that the current tool may have been missing.

[0107] In an embodiment of the present application, whichever of the number of fracture timing points, the number of wear timing points, and the number of missing timing points reaches the corresponding target preset life (target preset fracture life, target preset wear life, and target preset missing life) first, then the processing state of the current tool in the target monitoring process is determined to be the corresponding state (fracture state, wear state, missing state).

[0108] 207. If the processing state is a broken state, a worn state, or a missing state, a processing stop instruction is triggered, and an alarm message corresponding to the broken state, the worn state, or the missing state is output.

[0109] The alarm information can be output based on the monitoring interface of the embedded program. It should be noted that if the processing status is a broken state, a worn state, or a missing state, it means that continuing the processing may lead to problems such as reduced processing accuracy and increased safety risks. To avoid the above problems, in the embodiment of the present application, a processing stop command is triggered and an alarm message corresponding to the broken state, the worn state, or the missing state is output to prompt the operator to check.

[0110] The present application provides a tool state monitoring method based on software implementation. First, during the process of machining a target workpiece, when the target monitoring process is executed, the target process number corresponding to the target monitoring process is transmitted to the PLC program (data center software) in the CNC machine tool system, and the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program in the CNC machine tool system; secondly, the PLC program is instructed to periodically collect the real-time driving data of multiple timing points corresponding to the target process number according to a preset time interval, and obtain the corresponding timing point reference driving data according to the target process number and the timing point, and transmit the multiple real-time driving data of the timing points and the corresponding timing point reference driving data to the embedded program; finally, the embedded program is instructed to determine the current processing state of the tool in the target monitoring process based on the target monitoring process parameters and the multiple real-time driving data of the timing points and the corresponding timing point reference driving data. Compared with the prior art, the embodiment of the present application, through the interaction between the NC program, the PLC program and the embedded program, first transmits the target process number to the PLC program by the NC program to instruct the PLC program to collect real-time driving data of multiple timing points corresponding to the target process number, and obtains corresponding timing point reference driving data based on the target process number and the timing point. At the same time, the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program. Finally, the embedded program determines the current processing status of the tool in the target monitoring process based on the target monitoring process parameters, the real-time driving data of the multiple timing points and the corresponding timing point reference driving data. The monitoring of the tool status is realized based on software, without the need to collect data through sensors, avoiding the problem of inaccurate basic data caused by sensor errors, ensuring the accuracy of the basic data, and thus improving the accuracy of the tool processing status monitoring results.

[0111] Furthermore, as a response to the above Figure 1 The embodiment of the present application provides a tool status monitoring device based on software implementation, such as Figure 3 As shown, the device includes:

[0112] Information transmission module 31, real-time drive data acquisition module 32, tool processing state determination module 33;

[0113] The information transmission module 31 is used to transmit the target process number corresponding to the target monitoring process to the PLC program in the CNC machine tool system when the target monitoring process is executed during the processing of the target workpiece, and transmit the target monitoring process parameters corresponding to the target monitoring process to the embedded program in the CNC machine tool system;

[0114] The real-time drive data acquisition module 32 is used to instruct the PLC program to periodically acquire the real-time drive data of multiple timing points corresponding to the target process number at preset time intervals, obtain the corresponding timing point reference drive data based on the target process number and the timing point, and transmit the real-time drive data of the multiple timing points and the corresponding timing point reference drive data to the embedded program;

[0115] The tool processing state determination module 33 is used to instruct the embedded program to determine the processing state of the current tool in the target monitoring process based on the target monitoring process parameters, the real-time driving data of multiple timing points and the corresponding benchmark driving data of the timing points.

[0116] In a specific application scenario, the target monitoring process parameters include a target preset wear coefficient and a target preset wear life, a target preset fracture coefficient and a target preset fracture life, a target preset missing coefficient and a target preset missing life, and the tool processing state determination module is used to:

[0117] Calculate the ratio between the real-time driving data at each time point and the reference driving data at the corresponding time point in a time sequence order, and use each ratio as a target ratio;

[0118] If the target ratio is greater than the target preset fracture coefficient, the time sequence point corresponding to the target ratio is marked as a fracture time sequence point;

[0119] If the target ratio is less than the target preset fracture coefficient and greater than the target preset wear coefficient, the time sequence point corresponding to the target ratio is marked as a wear time sequence point;

[0120] If the target ratio is less than the target preset wear coefficient and greater than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a normal timing point;

[0121] If the target ratio is less than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a missing timing point;

[0122] Monitor the number of broken timing points, the number of worn timing points, and the number of missing timing points respectively;

[0123] If the number of the fracture timing points reaches the target preset fracture life first, then determining that the machining state of the current tool in the target monitoring process is a fracture state;

[0124] If the number of the wear time sequence points reaches the target preset wear life first, then determining that the current machining state of the tool in the target monitoring process is a wear state;

[0125] If the number of the missing timing points reaches the target preset missing life first, it is determined that the machining state of the current tool in the target monitoring process is a missing state.

[0126] In a specific application scenario, after the tool processing state determination module, the device further includes an alarm module for:

[0127] If the processing state is a broken state, a worn state, or a missing state, a processing stop instruction is triggered, and an alarm message corresponding to the broken state, the worn state, or the missing state is output.

[0128] In a specific application scenario, before the information transmission module, the device further includes a reference drive data acquisition module for:

[0129] When the current tool reaches an optimal state, processing the reference workpiece using the current tool;

[0130] During the machining of the reference workpiece, the process number corresponding to each expected monitoring process is transmitted to the PLC program in the CNC machine tool system;

[0131] Instructing the PLC program to periodically collect and store multiple sequential point reference drive data corresponding to each process number according to the preset time interval;

[0132] When it is monitored that the processing of the reference workpiece is completed, a reference drive data sampling end instruction is triggered to end the reference drive data sampling thread.

[0133] In a specific application scenario, the CNC machine tool system includes NC programs, PLC programs, and embedded programs;

[0134] The NC program is used to issue instructions to the PLC program and the embedded program, so that the PLC program and the embedded program execute tasks according to the instructions;

[0135] The PLC program is used to collect real-time drive data and benchmark drive data at sequential points;

[0136] The embedded program is used to determine the machining status of the tool.

[0137] In a specific application scenario, the embedded program also includes a monitoring interface for manual interaction to receive a reference drive data sampling start instruction and a reference drive data sampling end instruction, output the tool processing status, and output alarm information.

[0138] In a specific application scenario, the target preset missing coefficient is smaller than the target preset wear coefficient and smaller than the target preset fracture coefficient.

[0139] The present application provides a tool state monitoring device based on software implementation. First, during the process of machining a target workpiece, when the target monitoring process is executed, the target process number corresponding to the target monitoring process is transmitted to the PLC program (data center software) in the CNC machine tool system, and the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program in the CNC machine tool system; secondly, the PLC program is instructed to periodically collect the real-time driving data of multiple timing points corresponding to the target process number according to a preset time interval, and obtain the corresponding timing point reference driving data according to the target process number and the timing point, and transmit the multiple real-time driving data of the timing points and the corresponding timing point reference driving data to the embedded program; finally, the embedded program is instructed to determine the current processing state of the tool in the target monitoring process based on the target monitoring process parameters and the multiple real-time driving data of the timing points and the corresponding timing point reference driving data. Compared with the prior art, the embodiment of the present application, through the interaction between the NC program, the PLC program and the embedded program, first transmits the target process number to the PLC program by the NC program to instruct the PLC program to collect real-time driving data of multiple timing points corresponding to the target process number, and obtains corresponding timing point reference driving data based on the target process number and the timing point. At the same time, the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program. Finally, the embedded program determines the current processing status of the tool in the target monitoring process based on the target monitoring process parameters, the real-time driving data of the multiple timing points and the corresponding timing point reference driving data. The monitoring of the tool status is realized based on software, without the need to collect data through sensors, avoiding the problem of inaccurate basic data caused by sensor errors, ensuring the accuracy of the basic data, and thus improving the accuracy of the tool processing status monitoring results.

[0140] According to one embodiment of the present application, a storage medium is provided, wherein the storage medium stores at least one executable instruction. The computer executable instruction can execute the tool condition monitoring method based on software implementation in any of the above method embodiments.

[0141] Based on this understanding, the technical solution of the present application can be embodied in the form of a software product, which can be stored in a non-volatile storage medium (which can be a CD-ROM, USB flash drive, mobile hard disk, etc.), including a number of instructions for enabling a computer device (which can be a personal computer, server, or network device, etc.) to execute the methods described in each implementation scenario of the present application.

[0142] Figure 4 A schematic diagram of the structure of a terminal provided according to an embodiment of the present application is shown. The specific embodiment of the present application does not limit the specific implementation of the terminal.

[0143] like Figure 4 As shown, the terminal may include: a processor (processor) 402 , a communications interface (Communications Interface) 404 , a memory (memory) 406 , and a communication bus 408 .

[0144] The processor 402 , the communication interface 404 , and the memory 406 communicate with each other via a communication bus 408 .

[0145] The communication interface 404 is used to communicate with other devices such as clients or other servers.

[0146] The processor 402 is configured to execute the program 410 , and specifically to execute the relevant steps in the above-mentioned embodiment of the tool state monitoring method based on software implementation.

[0147] Specifically, the program 410 may include program codes, which include computer operation instructions.

[0148] Processor 402 may be a central processing unit (CPU), an application-specific integrated circuit (ASIC), or one or more integrated circuits configured to implement the embodiments of the present application. The one or more processors included in a computer device may be processors of the same type, such as one or more CPUs, or may be processors of different types, such as one or more CPUs and one or more ASICs.

[0149] The memory 406 is used to store the program 410. The memory 406 may include a high-speed RAM memory, and may also include a non-volatile memory (non-volatile memory), such as at least one disk memory.

[0150] The program 410 may be specifically configured to cause the processor 402 to perform the following operations:

[0151] During the process of machining the target workpiece, when the target monitoring process is executed, the target process number corresponding to the target monitoring process is transmitted to the PLC program (data center software) in the CNC machine tool system, and the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program in the CNC machine tool system;

[0152] Instructing the PLC program to periodically collect real-time driving data of a plurality of timing points corresponding to the target process number at preset time intervals, obtain corresponding timing point reference driving data according to the target process number and the timing point, and transmit the plurality of real-time driving data of the timing points and the corresponding timing point reference driving data to the embedded program;

[0153] The embedded program is instructed to determine the machining state of the current tool in the target monitoring process based on the target monitoring process parameters and the real-time driving data of the plurality of sequential points and the corresponding benchmark driving data of the sequential points.

[0154] The storage medium may also include an operating system and a network communication module. The operating system is a program that manages the hardware and software resources of the physical device implementing the software-based tool condition monitoring method, supporting the execution of the information processing program and other software and / or programs. The network communication module is used to enable communication between components within the storage medium and with other hardware and software within the physical information processing device.

[0155] Each embodiment in this specification is described in a progressive manner, with each embodiment focusing on its differences from the other embodiments. References to the same or similar parts between the various embodiments are sufficient. For system embodiments, since they are generally similar to the method embodiments, their description is relatively simple. For relevant parts, references to the description of the method embodiments are sufficient.

[0156] The methods and systems of the present application may be implemented in many ways. For example, the methods and systems of the present application may be implemented by software, hardware, firmware, or any combination of software, hardware, and firmware. The above order of steps for the method is for illustration only, and the steps of the method of the present application are not limited to the order specifically described above, unless otherwise specifically stated. In addition, in some embodiments, the present application may also be implemented as programs recorded in a recording medium, which include machine-readable instructions for implementing the methods according to the present application. Therefore, the present application also covers recording media that store programs for executing the methods according to the present application.

[0157] Obviously, those skilled in the art should understand that the modules or steps of the present application described above can be implemented using a general-purpose computing device, they can be concentrated on a single computing device, or distributed on a network composed of multiple computing devices. Alternatively, they can be implemented using program code executable by the computing device, so that they can be stored in a storage device and executed by the computing device. In some cases, the steps shown or described can be performed in a different order than herein, or they can be made into separate integrated circuit modules, or multiple modules or steps can be made into a single integrated circuit module for implementation. Thus, the present application is not limited to any specific combination of hardware and software.

[0158] The above description is merely a preferred embodiment of the present application and is not intended to limit the present application. Persons skilled in the art will readily appreciate that various modifications and variations are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.

Claims

1. A tool condition monitoring method based on software, characterized in that: NC programs (command software) used in CNC machine tool systems include: During the process of machining the target workpiece, when the target monitoring process is executed, the target process number corresponding to the target monitoring process is transmitted to the PLC program (data center software) in the CNC machine tool system, and the target monitoring process parameters corresponding to the target monitoring process are transmitted to the embedded program in the CNC machine tool system; Instructing the PLC program to periodically collect real-time driving data of a plurality of timing points corresponding to the target process number at preset time intervals, obtain corresponding timing point reference driving data according to the target process number and the timing point, and transmit the plurality of real-time driving data of the timing points and the corresponding timing point reference driving data to the embedded program; The embedded program is instructed to determine the machining state of the current tool in the target monitoring process based on the target monitoring process parameters and the real-time driving data of the plurality of sequential points and the corresponding benchmark driving data of the sequential points.

2. The method according to claim 1, characterized in that The target monitoring process parameters include a target preset wear coefficient and a target preset wear life, a target preset fracture coefficient and a target preset fracture life, a target preset missing coefficient and a target preset missing life. Based on the target monitoring process parameters, according to the real-time driving data of the plurality of sequential points and the corresponding benchmark driving data of the sequential points, determining the machining state of the current tool in the target monitoring process includes: Calculate the ratio between the real-time driving data at each time point and the reference driving data at the corresponding time point in a time sequence order, and use each ratio as a target ratio; If the target ratio is greater than the target preset fracture coefficient, the time point corresponding to the target ratio is marked as a fracture time point; If the target ratio is less than the target preset fracture coefficient and greater than the target preset wear coefficient, the time sequence point corresponding to the target ratio is marked as a wear time sequence point; If the target ratio is less than the target preset wear coefficient and greater than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a normal timing point; If the target ratio is less than the target preset missing coefficient, the timing point corresponding to the target ratio is marked as a missing timing point; Monitor the number of broken timing points, the number of worn timing points, and the number of missing timing points respectively; If the number of the fracture timing points reaches the target preset fracture life first, then determining that the machining state of the current tool in the target monitoring process is a fracture state; If the number of the wear time sequence points reaches the target preset wear life first, then determining that the current machining state of the tool in the target monitoring process is a wear state; If the number of the missing timing points reaches the target preset missing life first, it is determined that the machining state of the current tool in the target monitoring process is a missing state.

3. The method according to claim 1, characterized in that After determining the machining state of the current tool in the target monitoring process based on the target monitoring process parameters and the real-time driving data of the plurality of sequential points and the corresponding benchmark driving data of the sequential points, the method further includes: If the processing state is a broken state, a worn state, or a missing state, a processing stop instruction is triggered, and an alarm message corresponding to the broken state, the worn state, or the missing state is output.

4. The method according to claim 1, wherein During the process of machining the target workpiece, when the target monitoring process is executed, before transmitting the target process number corresponding to the target monitoring process to the PLC program in the CNC machine tool system and transmitting the target monitoring process parameters corresponding to the target monitoring process to the embedded program in the CNC machine tool system, the method further includes: When the current tool reaches an optimal state, processing the reference workpiece using the current tool; During the machining of the reference workpiece, the process number corresponding to each expected monitoring process is transmitted to the PLC program in the CNC machine tool system; Instructing the PLC program to periodically collect and store multiple sequential point reference drive data corresponding to each process number according to the preset time interval; When it is monitored that the processing of the reference workpiece is completed, a reference drive data sampling end instruction is triggered to end the reference drive data sampling thread.

5. The method according to claim 1, wherein The CNC machine tool system includes NC program, PLC program and embedded program; The NC program is used to issue instructions to the PLC program and the embedded program, so that the PLC program and the embedded program execute tasks according to the instructions; The PLC program is used to collect real-time drive data and benchmark drive data at sequential points; The embedded program is used to determine the machining status of the tool.

6. The method according to claim 5, characterized in that The embedded program also includes a monitoring interface for manual interaction to receive a reference drive data sampling start instruction and a reference drive data sampling end instruction, output a tool processing status, and output alarm information.

7. The method according to claim 2, characterized in that The target preset missing coefficient is smaller than the target preset wear coefficient and smaller than the target preset fracture coefficient.

8. A tool status monitoring device based on software, characterized in that: NC programs used in CNC machine tool systems include: An information transmission module is used to transmit, when a target monitoring process is executed during the processing of a target workpiece, a target process number corresponding to the target monitoring process to a PLC program in a CNC machine tool system, and to transmit target monitoring process parameters corresponding to the target monitoring process to an embedded program in the CNC machine tool system; a real-time drive data acquisition module, configured to instruct the PLC program to periodically acquire real-time drive data of a plurality of sequential points corresponding to the target process number at preset time intervals, obtain corresponding sequential point reference drive data based on the target process number and the sequential point, and transmit the plurality of real-time drive data of the sequential points and the corresponding sequential point reference drive data to the embedded program; The tool processing state determination module is used to instruct the embedded program to determine the processing state of the current tool in the target monitoring process based on the target monitoring process parameters, the real-time driving data of multiple timing points and the corresponding timing point reference driving data.

9. A storage medium storing at least one executable instruction, characterized in that: The executable instructions enable the processor to execute operations corresponding to the tool condition monitoring method implemented based on software as described in any one of claims 1 to 7.

10. A terminal comprising: A processor, a memory, a communication interface, and a communication bus, wherein the processor, the memory, and the communication interface communicate with each other via the communication bus; The memory is used to store at least one executable instruction, wherein the executable instruction enables the processor to execute an operation corresponding to the tool condition monitoring method based on software implementation as described in any one of claims 1 to 7.

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