Machine tool spindle operation and maintenance system based on digital twinning

Abstract

The invention discloses a machine tool spindle operation and maintenance system based on digital twinning. Real data are collected after the equipment state is initialized; the data items of the real data comprise machine tool operation parameters, main shaft rotating speed, feeding amount, machine tool main shaft temperature and machine tool main shaft vibration amplitude, one-to-one modeling is carried out on the EDM machine tool based on the digital twinning technology, a digital twinning model of the EDM machine tool is obtained, and the physical machine tool is connected with the digital twinning model through the Internet of Things technology. According to the invention, real-time monitoring, fault prediction and accurate maintenance of the equipment operation state are realized through the rule base.

Description

Technical Field

[0001] This invention relates to the field of operation and maintenance system technology, and more specifically, to a machine tool spindle operation and maintenance system based on digital twins. Background Technology

[0002] Traditional equipment inspection and maintenance methods often rely on manual inspections and periodic maintenance, which are not only inefficient but also ill-suited to complex and ever-changing industrial environments. As equipment becomes increasingly complex, traditional inspection methods are insufficient to meet the demands for real-time monitoring and precise maintenance of equipment operating status. Currently, some intelligent inspection technologies, such as vibration monitoring and temperature monitoring, are being applied to industrial equipment maintenance. However, these technologies only provide single-dimensional data and cannot comprehensively reflect the equipment's operating status. Furthermore, they lack real-time and predictive capabilities, failing to detect potential faults in advance, resulting in high maintenance costs and low efficiency. On the other hand, digital twin technology, as an emerging digital tool, has demonstrated enormous application potential in multiple fields. In the field of intelligent equipment inspection and maintenance, the application of digital twin technology is still in its early stages. Therefore, there is an urgent need for an intelligent inspection method capable of real-time monitoring and precise prediction of equipment operating status. In addition, traditional EDM machines lack real-time monitoring capabilities. Most equipment relies on periodic inspections to identify problems, which is not only inefficient but also prone to delayed problem detection, failing to address the risks posed by abnormal discharges or electrode wear in a timely manner. In addition, many machine tools lack intelligent sensors and data acquisition systems, making it impossible to acquire and analyze key discharge parameters in real time, thus preventing the dynamic adjustment of machining parameters to optimize the process. Summary of the Invention

[0003] (a) Technical problems to be solved

[0004] In view of the problems existing in the prior art, the present invention provides a machine tool spindle operation and maintenance system based on digital twin to solve the technical problems mentioned in the background art.

[0005] (II) Technical Solution

[0006] To achieve the above objectives, the present invention provides the following technical solution: a machine tool spindle maintenance system based on digital twins, comprising the following steps:

[0007] Step 1: After initializing the equipment status, collect real data; the data items of the real data include: machine tool operating parameters, spindle speed, feed rate, machine tool spindle temperature and machine tool spindle vibration amplitude. Based on digital twin technology, model the EDM machine tool one-to-one to obtain the digital twin model of the EDM machine tool, and connect the physical machine tool and the digital twin model through Internet of Things technology.

[0008] Step 2: Collect discharge parameters from the digital twin model of the EDM machine when machining the same part of each part in the same batch, analyze the discharge stability coefficient of the EDM machine when machining each part in the same batch, and identify whether there is abnormal discharge behavior in the EDM machine based on it; if abnormal discharge behavior is identified, corresponding operation and maintenance adjustments are made to the EDM machine.

[0009] Step 3: Simulate the machining process using CNC simulation to optimize tool parameters and machining parameters; then further optimize fixture parameters, tool parameters, and machining parameters using finite element analysis; construct a digital twin model based on the equipment; preprocess the real data using a virtual-real interaction module; and input the preprocessed real data into the digital twin model to achieve virtual-real synchronization.

[0010] Step 4: Construct a database including equipment operation and maintenance index system based on the simulation data generated by the digital twin model and the preprocessed real data. Number each part in the same batch sequentially. Through the electrode wear monitoring sensor equipped on the physical machine tool, send the initial volume of each part in the same batch processed by the EDM electrode in real time to the digital twin model. Analyze the wear rate of the electrode through the algorithm. If the wear rate of the electrode is greater than the set wear threshold, the processing parameters of the EDM machine tool will be automatically adjusted.

[0011] Step 5: Construct a database including an equipment operation and maintenance indicator system based on the simulation data generated by the digital twin model and the preprocessed real data; construct a rule base based on the data in the database and the equipment operation and maintenance indicator system; the rule base is used to determine the current operating status of the equipment; the rule base includes: simple events, event association rules, and complex event streams.

[0012] The present invention is further configured such that the optimized fixture parameters, tool parameters, and machining parameters are used to establish a three-dimensional model using ProcessSimulate software, and the three-dimensional model is laid out according to the drawings to build a virtual production line.

[0013] The present invention is further configured such that, in the virtual production line formed, the process requiring human intervention is simulated and evaluated using Process Simulate software by setting the motion parameters of the human body model, and the comfort and workload of the human body model are analyzed using ergonomic standards, thereby optimizing the motion parameters of the human body model.

[0014] The present invention is further configured to include: generating maintenance instructions based on the complex event stream, and adjusting the equipment in real time.

[0015] The present invention is further configured to use Process Simulate software to decompose the actions of the equipment model according to a preset process flow sequence, set the constraint relationship and movement range of the moving parts in the equipment model, set the corresponding coordinate system for the workpiece model and the robot model, and design the transport path of the robot model according to the preset process flow sequence.

[0016] The present invention is further configured to connect the virtual production line electrical environment and the actual PLC controller through a virtual PLC controller, so that the actual PLC controller drives the three-dimensional model of the virtual production line electrical environment, and verifies and debugs the actual PLC controller and robot program of the actual production line.

[0017] The present invention is further configured to include: visually displaying the digital twin model, the current equipment status, the settings of the equipment parameters, and the maintenance plan for the abnormal equipment status.

[0018] The present invention is further configured to include: sending and receiving the real data in real time through a virtual-real interaction module; and temporarily storing the simulation data and the real data.

[0019] The present invention is further configured such that, based on the calculation method for determining the authenticity of the corresponding voltage anomaly of the EDM machine tool, the authenticity of the corresponding current anomaly, pulse continuity anomaly, and pulse interval anomaly of the EDM machine tool are similarly determined; if the authenticity of the corresponding current anomaly of the EDM machine tool is True, then the anomaly type of the EDM machine tool with abnormal discharge behavior is determined to be current anomaly; if the authenticity of the corresponding pulse continuity anomaly of the EDM machine tool is True, then the anomaly type of the EDM machine tool with abnormal discharge behavior is determined to be pulse continuity anomaly; if the authenticity of the corresponding pulse interval anomaly of the EDM machine tool is True, then the anomaly type of the EDM machine tool with abnormal discharge behavior is determined to be pulse interval anomaly; by combining the above judgment process, the anomaly type of the EDM machine tool with abnormal discharge behavior is comprehensively determined.

[0020] The present invention is further configured to establish a tool model and a workpiece model through the Vericut CNC simulation system, input G-code, verify the G-code in the Vericut CNC simulation system, call the machine tool simulation module to simulate the machining process, and check whether there is overcutting or undercutting to prevent machine tool collisions, overtravel and other errors, and optimize tool parameters and machining parameters.

[0021] (III) Beneficial Effects

[0022] Compared with existing technologies, this invention provides a machine tool spindle maintenance system based on digital twins, which has the following advantages:

[0023] In this invention, multi-dimensional simulation data is generated from a digital twin model; a database including an equipment operation and maintenance indicator system is constructed based on the simulation data and real data; a rule base is constructed based on the data in the database and the equipment operation and maintenance indicator system; the current operating status of the equipment is determined through the rule base; and real-time monitoring, fault prediction, and precise maintenance of the equipment's operating status are achieved through the rule base. Furthermore, this embodiment of the invention effectively assesses the discharge stability of an EDM machine by monitoring and analyzing the discharge parameters of each part within the same batch being processed, thereby identifying any abnormal discharge behavior. This process is necessary because abnormal discharge not only leads to a decrease in processing accuracy but may also cause equipment damage, increasing production costs and downtime. Therefore, timely identification and adjustment of abnormal discharge behavior is a crucial step in ensuring the normal operation of the equipment. Analysis of the discharge stability coefficient provides information on the consistency and reliability of the discharge during the EDM machine's processing. By comparing the discharge parameters of parts in the same batch, potential abnormal fluctuations can be detected. These fluctuations may be caused by uneven electrode wear, unstable working fluid pressure, or equipment malfunction. Once these anomalies are identified, the EDM machine can be immediately adjusted for operation and maintenance, thereby restoring processing stability and accuracy. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of a machine tool spindle maintenance system based on digital twins according to the present invention. Detailed Implementation

[0025] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0026] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0027] In this invention, unless otherwise stated, the directional terms such as "up" and "down" generally refer to the directions shown in the accompanying drawings, or to the vertical, perpendicular, or gravitational direction; similarly, for ease of understanding and description, "left" and "right" generally refer to the left and right shown in the accompanying drawings; "inner" and "outer" refer to the inner and outer contours of each component itself, but the above directional terms are not intended to limit this invention.

[0028] Example 1:

[0029] Please see Figure 1 A machine tool spindle maintenance system based on digital twins includes the following steps:

[0030] Step 1: After initializing the equipment status, collect real data; the data items of the real data include: machine tool operating parameters, spindle speed, feed rate, machine tool spindle temperature and machine tool spindle vibration amplitude. Based on digital twin technology, model the EDM machine tool one-to-one to obtain the digital twin model of the EDM machine tool, and connect the physical machine tool and the digital twin model through Internet of Things technology.

[0031] Step 2: Collect discharge parameters from the digital twin model of the EDM machine when machining the same part of each part in the same batch, analyze the discharge stability coefficient of the EDM machine when machining each part in the same batch, and identify whether there is abnormal discharge behavior in the EDM machine based on it; if abnormal discharge behavior is identified, corresponding operation and maintenance adjustments are made to the EDM machine.

[0032] Step 3: Simulate the machining process using CNC simulation to optimize tool parameters and machining parameters; then further optimize fixture parameters, tool parameters, and machining parameters using finite element analysis; construct a digital twin model based on the equipment; preprocess the real data using a virtual-real interaction module; and input the preprocessed real data into the digital twin model to achieve virtual-real synchronization.

[0033] Step 4: Construct a database including equipment operation and maintenance index system based on the simulation data generated by the digital twin model and the preprocessed real data. Number each part in the same batch sequentially. Through the electrode wear monitoring sensor equipped on the physical machine tool, send the initial volume of each part in the same batch processed by the EDM electrode in real time to the digital twin model. Analyze the wear rate of the electrode through the algorithm. If the wear rate of the electrode is greater than the set wear threshold, the processing parameters of the EDM machine tool will be automatically adjusted.

[0034] Step 5: Construct a database including an equipment operation and maintenance indicator system based on the simulation data generated by the digital twin model and the preprocessed real data; construct a rule base based on the data in the database and the equipment operation and maintenance indicator system; the rule base is used to determine the current operating status of the equipment; the rule base includes: simple events, event association rules, and complex event streams.

[0035] In a further embodiment of the present invention, the optimized fixture parameters, tool parameters, and machining parameters are used to establish a three-dimensional model using Process Simulate software, and a virtual production line is built based on the layout of the three-dimensional model according to the drawings. For processes requiring manual intervention in the formed virtual production line, Process Simulate software is used to simulate and evaluate the accessibility and visibility of the processes requiring manual intervention by setting the motion parameters of a human body model. The comfort and workload of the human body model are analyzed using ergonomic standards, and the motion parameters of the human body model are then optimized. The invention also includes generating maintenance instructions based on the complex event flow to control the equipment in real time.

[0036] Example 2:

[0037] A machine tool spindle maintenance system based on digital twins includes the following steps:

[0038] Step 1: After initializing the equipment status, collect real data; the data items of the real data include: machine tool operating parameters, spindle speed, feed rate, machine tool spindle temperature and machine tool spindle vibration amplitude. Based on digital twin technology, model the EDM machine tool one-to-one to obtain the digital twin model of the EDM machine tool, and connect the physical machine tool and the digital twin model through Internet of Things technology.

[0039] Step 2: Collect discharge parameters from the digital twin model of the EDM machine when machining the same part of each part in the same batch, analyze the discharge stability coefficient of the EDM machine when machining each part in the same batch, and identify whether there is abnormal discharge behavior in the EDM machine based on it; if abnormal discharge behavior is identified, corresponding operation and maintenance adjustments are made to the EDM machine.

[0040] Step 3: Simulate the machining process using CNC simulation to optimize tool parameters and machining parameters; then further optimize fixture parameters, tool parameters, and machining parameters using finite element analysis; construct a digital twin model based on the equipment; preprocess the real data using a virtual-real interaction module; and input the preprocessed real data into the digital twin model to achieve virtual-real synchronization.

[0041] Step 4: Construct a database including equipment operation and maintenance index system based on the simulation data generated by the digital twin model and the preprocessed real data. Number each part in the same batch sequentially. Through the electrode wear monitoring sensor equipped on the physical machine tool, send the initial volume of each part in the same batch processed by the EDM electrode in real time to the digital twin model. Analyze the wear rate of the electrode through the algorithm. If the wear rate of the electrode is greater than the set wear threshold, the processing parameters of the EDM machine tool will be automatically adjusted.

[0042] Step 5: Construct a database including an equipment operation and maintenance indicator system based on the simulation data generated by the digital twin model and the preprocessed real data; construct a rule base based on the data in the database and the equipment operation and maintenance indicator system; the rule base is used to determine the current operating status of the equipment; the rule base includes: simple events, event association rules, and complex event streams.

[0043] In a further embodiment of this application, Process Simulate software is used to decompose the actions of the equipment model according to a preset process flow sequence, and to set the constraint relationships and movement ranges of the moving parts in the equipment model. Then, corresponding coordinate systems are set for the workpiece model and the robot model, and the transport path of the robot model is designed according to the preset process flow sequence. The virtual production line electrical environment and the actual PLC controller are connected through a virtual PLC controller, and the actual PLC controller drives the three-dimensional model of the virtual production line electrical environment. The actual PLC controller and robot program of the actual production line are verified and debugged. The application also includes: visually displaying the digital twin model, the current equipment status, the settings of each parameter of the equipment, and the maintenance plan for abnormal equipment status.

[0044] The invention is further configured to include: sending and receiving the real data in real time through a virtual-real interaction module; temporarily storing the simulation data and the real data; similarly determining the authenticity of the EDM machine tool in the corresponding current anomaly, pulse continuity anomaly, and pulse interval anomaly based on the calculation method for determining the authenticity of the corresponding voltage anomaly; if the authenticity of the EDM machine tool in the corresponding current anomaly is True, then the abnormality type of the EDM machine tool with abnormal discharge behavior is determined to be current anomaly; if the authenticity of the EDM machine tool in the corresponding pulse continuity anomaly is True, then the abnormality type of the EDM machine tool with abnormal discharge behavior is determined to be pulse continuity anomaly; if the authenticity of the EDM machine tool in the corresponding pulse interval anomaly is True, then the abnormality type of the EDM machine tool with abnormal discharge behavior is determined to be pulse interval anomaly; combining the above judgment process, the abnormality type of the EDM machine tool with abnormal discharge behavior is comprehensively determined; a tool model and a workpiece model are established through the Veri Cut CNC simulation system, and G-code is input, in Veri... Verify G-code in the CNC simulation system; call the machine tool simulation module to simulate the machining process and check for overcutting or undercutting to prevent machine tool collisions, overtravel and other errors, and optimize tool parameters and machining parameters.

[0045] Of all the solutions mentioned above, those involving the connection between two components can be selected according to the actual situation, such as welding, bolt and nut connection, bolt or screw connection, or other known connection methods, which will not be elaborated here. For all the fixed connections mentioned above, welding is preferred. Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A machine tool spindle operation and maintenance system based on digital twinning, characterized in that, It comprises the following steps: Step one: collect real data after the equipment state initialization; The data items of the real data include machine tool operating parameters, spindle speed, feed amount, machine tool spindle temperature and machine tool spindle vibration amplitude, a one-to-one modeling of the electric spark machine tool is carried out based on digital twin technology, the digital twin model of the electric spark machine tool is obtained, and the physical machine tool is connected with the digital twin model through Internet of Things technology; Step two: collect the discharge parameters of the electric spark machine tool when machining the same parts of the same batch by the digital twin model of the electric spark machine tool, analyze the discharge stability coefficient of the electric spark machine tool when machining the same parts of the same batch, and identify whether the electric spark machine tool has abnormal discharge behavior based on it; if the electric spark machine tool has abnormal discharge behavior, the electric spark machine tool is adjusted and operated correspondingly; Step three: simulate the mechanical machining process through numerical control simulation, optimize the tool parameters, machining parameters; then continue to optimize the fixture parameters, tool parameters and machining parameters through finite element analysis, build a digital twin model according to the equipment, preprocess the real data through virtual-real interaction module, and input the preprocessed real data into the digital twin model to realize virtual-real synchronization; Step four: according to the simulation data generated by the digital twin model and the preprocessed real data, a database including equipment operation and maintenance index system is constructed, each part of the same batch is numbered in turn, the initial volume of the electric spark machine tool electrode in machining each part of the same batch is sent to the digital twin model through the electrode wear monitoring sensor equipped on the physical machine tool, the wear rate of the electrode is analyzed through algorithm, and if the wear rate of the electrode is greater than the set wear threshold, the machining parameters of the electric spark machine tool are automatically adjusted; Step five: according to the simulation data generated by the digital twin model and the preprocessed real data, a database including equipment operation and maintenance index system is constructed, and a rule base is constructed according to the data of the database and the equipment operation and maintenance index system; the rule base is used to determine the running state of the current equipment; the rule base includes simple events, event association rules and complex event streams.

2. The machine tool spindle operation and maintenance system based on digital twinning according to claim 1, characterized in that: The optimized fixture parameters, tool parameters and machining parameters are used to establish a three-dimensional model through Process Simulate software, and the three-dimensional model is laid out according to the drawing to build a virtual production line.

3. The machine tool spindle operation and maintenance system based on digital twinning according to claim 2, characterized in that: The process that needs manual participation in the formed virtual production line is simulated and evaluated through Process Simulate software by setting the action parameters of the human body model to analyze the reachability and visibility of the process that needs manual participation, and the comfort and work intensity of the human body model are analyzed through ergonomics standards, and then the action parameters of the human body model are optimized.

4. The machine tool spindle operation and maintenance system based on digital twinning according to claim 1, characterized in that: It also includes: According to the complex event stream, a maintenance instruction is generated to real-time control the equipment.

5. The machine tool spindle operation and maintenance system based on digital twinning according to claim 4, characterized in that: The action of the equipment model is decomposed according to the preset process flow sequence by using Process Simulate software, and the constraint relationship and motion range of the moving parts in the equipment model are set, and then the coordinate system of the workpiece model and the robot model is set, and the carrying path of the robot model is designed according to the preset process flow sequence.

6. The machine tool spindle operation and maintenance system based on digital twinning according to claim 5, characterized in that: The virtual production line electrical environment and the actual PLC controller are connected through the virtual PLC controller, the three-dimensional model of the virtual production line electrical environment is driven by the actual PLC controller, and the actual PLC controller and the robot program of the actual production line are verified and debugged.

7. The machine tool spindle operation and maintenance system based on digital twinning according to claim 1, characterized in that: Also includes: The digital twin model, the current equipment state, the equipment parameter setting and the equipment state abnormality maintenance scheme are visually displayed.

8. The machine tool spindle operation and maintenance system based on digital twinning according to claim 7, characterized in that: Also includes: The real data are sent and received in real time through the virtual-real interaction module; The simulation data and the real data are temporarily stored.

9. The machine tool spindle operation and maintenance system based on digital twinning according to claim 7, characterized in that: The calculation method of the realness of the electric spark machine tool corresponding to the voltage abnormality is the same as the realness of the electric spark machine tool corresponding to the current abnormality, the pulse duration abnormality and the pulse interval abnormality; If the realness of the electric spark machine tool corresponding to the current abnormality is True, it is determined that the abnormal type of the abnormal discharge behavior of the electric spark machine tool is current abnormality; if the realness of the electric spark machine tool corresponding to the pulse duration abnormality is True, it is determined that the abnormal type of the abnormal discharge behavior of the electric spark machine tool is pulse duration abnormality; If the realness of the electric spark machine tool corresponding to the pulse interval abnormality is True, it is determined that the abnormal type of the abnormal discharge behavior of the electric spark machine tool is pulse interval abnormality; according to the above judgment process, the abnormal type of the abnormal discharge behavior of the electric spark machine tool is comprehensively determined.

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