Method and system for displaying real-time data of tool machining state

Abstract

The invention relates to the technical field of numerical control machine tool cutter monitoring, in particular to a cutter machining state real-time data display method and system, and the method comprises the steps that cutter process quantity signals collected and transmitted by a monitoring module are received, and the process quantity signals at least comprise transverse bending moment and tangential bending moment; according to a user instruction, taking transverse bending moment and tangential bending moment data in the process quantity signal as two-dimensional coordinate points, and displaying the two-dimensional coordinate points in a polar coordinate graph in a scattered point form; according to the invention, through real-time stable monitoring of the process quantity signal of the cutter handle and fitting of the acquired data, the original data can be displayed and optimized in the coordinates of the pole figure, and the proportion is adjusted by the scale factor to realize interaction, so that the characteristics of the cutter are amplified and remarkable to a great extent; a user can preliminarily judge the machining operation state and the tool abrasion condition based on the pole graph, meanwhile, data are presented in the pole graph in a scattered point mode, and the change of the data is matched with the real-time machining state.

Description

Technical Field

[0001] This invention relates to the field of CNC machine tool tool monitoring, and in particular to a method and system for displaying real-time data on tool machining status. Background Technology

[0002] In the field of CNC machining, tool condition monitoring is a crucial link in ensuring machining accuracy, efficiency, and reliability. However, traditional monitoring methods mainly rely on manual periodic inspections, judging the degree of tool wear through visual inspection or simple tools. This method cannot capture the changes in the tool's condition in real time during dynamic machining processes. The monitoring of key operating parameters such as temperature and vibration is lagging, making it difficult to reflect the actual working state of the tool under complex cutting conditions, resulting in insufficient timeliness and accuracy of monitoring.

[0003] Currently, some intelligent cutting tools can achieve automatic detection, but the display interface of their monitoring software suffers from insensitivity to feature effects. Their data visualization is often limited to simple numerical values ​​or basic curve displays, failing to deeply extract and intuitively present key features such as tool wear, temperature fluctuations, and abnormal vibrations. This deficiency makes it difficult for operators to quickly identify subtle changes in tool condition, hindering the adaptive machining system from adjusting cutting parameters according to real-time working conditions.

[0004] Furthermore, tool wear, as a gradual change in the machining process, is influenced by multiple factors such as material properties, cutting parameters, and working environment. Traditional methods, lacking real-time data-driven and precise modeling capabilities, struggle to scientifically predict wear trends. This leads to maintenance plans relying on experience-based estimations, which can result in over-maintenance or under-maintenance, increasing production costs and equipment failure risks. Summary of the Invention

[0005] The purpose of this invention is to address the problem that the display interface of existing monitoring software is not sensitive to feature effects, and its data visualization is often limited to simple numerical or basic curve displays, failing to deeply extract and intuitively present key features such as tool wear, temperature fluctuations, and abnormal vibrations. Therefore, this invention proposes a method and system for displaying real-time data of tool processing status.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] The first aspect of this invention discloses a method for displaying real-time data on the machining status of a cutting tool, the method comprising:

[0008] Receive tool process quantity signals acquired and transmitted by the monitoring module, the process quantity signals including at least transverse bending moment and tangential bending moment;

[0009] According to user instructions, the transverse bending moment and tangential bending moment data in the process quantity signal are used as two-dimensional coordinate points (xi, yi) and displayed as scattered points in the polar coordinate graph;

[0010] Based on the set of two-dimensional coordinate points, an optimal circle is fitted using the least squares method, and the center coordinates O(a, b) and radius R of the fitted circle are calculated.

[0011] The system receives the scale factor P set by the user, and based on the center coordinates (a, b), radius R, and scale factor P, it radially shrinks each original data point (xi, yi) along the direction pointing to the center of the circle, generating and outputting a new set of transformed data points.

[0012] Furthermore, after generating and outputting a new set of transformed data points, the method further includes:

[0013] Based on the transformed data points, the scatter plot in the display interface is updated and refreshed, and the display interface is presented in the host computer software.

[0014] Furthermore, the step of fitting an optimal circle using the least squares method based on the set of two-dimensional coordinate points, and calculating the center coordinates O(a, b) and radius R of the fitted circle, includes:

[0015] Let the general equation of a circle be: (x - a)² + (y - b)² = R²;

[0016] Transform the general equation into linear form: x² + y² + Ax + By + C = 0;

[0017] The parameters A, B, C are related to the center coordinates (a, b) and radius R as follows: A = -2a, B = -2b, C = a² + b² - R²;

[0018] The objective function E(A, B, C) for the sum of squared errors is constructed as follows:

[0019]

[0020] Where i ranges from 1 to n, and n is the total number of data points in the set of two-dimensional coordinate points.

[0021] Furthermore, the step of fitting an optimal circle using the least squares method based on the set of two-dimensional coordinate points, and calculating the center coordinates (a, b) and radius R of the fitted circle, also includes:

[0022] To find the minimum value, we need to calculate the partial derivatives with respect to A, B, and C respectively and set them to zero, resulting in:

[0023]

[0024]

[0025]

[0026] Construct a system of three linear equations in terms of A, B, and C based on the partial derivative equations. Solve for A and B using a 2x2 linear system, and then solve for C. The solution method is matrix inversion. The linear system is as follows:

[0027]

[0028] Where M11, M12, and M22 are the coefficients for solving the 2x2 matrices of A and B, and MR1 and MR2 are the vectors on the right side of the linear equation system.

[0029] After obtaining the values ​​of A, B, and C, according to the formula a = -A / 2, b = -B / 2, R = The center coordinates O(a, b) and radius R of the fitted circle are calculated.

[0030] Furthermore, the step of receiving the user-defined scaling factor P, and based on the center coordinates (a, b), radius R, and scaling factor P, radially shrinking each original data point (xi, yi) along its direction pointing to the center, to generate and output a new set of transformed data points includes:

[0031] Receives a user-defined scaling factor P, where the value of P ranges from 0% to 100%.

[0032] The absolute shrinkage distance d is calculated according to the formula d = R x P, where d is the distance that the original data point (xi, yi) needs to move towards the center of the circle.

[0033] For each original data point (xi, yi), perform the following operations:

[0034] Calculate the vector V from the point to the fitted circle center O(a, b): V = (xi - a, yi - b);

[0035] Calculate the distance r from the point to the fitted circle center O(a, b): ;

[0036] According to the formula = r – d, calculate the new distance after contraction .

[0037] Furthermore, if If ≥ 0, then by formula N = O + ( The transformed new data point N is obtained by calculating ( / r) x V;

[0038] like If < 0, then discard the original data point.

[0039] Furthermore, after receiving the tool process quantity signal collected and transmitted by the monitoring module, the method further includes:

[0040] The process quantity signal is displayed in real time in a display format selected by the user, wherein the display format includes one or more of digital instruments, scatter plots, line graphs or bar charts.

[0041] Furthermore, the process quantity signals are acquired by a sensing module mounted on the tool holder to monitor the pressure, torque, lateral bending moment, and tangential bending moment during the tool machining process. The sensing module internally employs a full-bridge circuit composed of strain gauges to convert the aforementioned physical quantities into electrical signals.

[0042] A second aspect of this invention discloses a display system for real-time data on tool machining status, the display system comprising:

[0043] The receiving unit receives the tool process quantity signals collected and transmitted by the monitoring module, the process quantity signals including at least the transverse bending moment and the tangential bending moment;

[0044] The generation unit, according to user instructions, uses the transverse bending moment and tangential bending moment data in the process quantity signal as two-dimensional coordinate points (xi, yi), and displays them in the form of scattered points on the polar coordinate graph;

[0045] The fitting unit, based on the set of two-dimensional coordinate points, fits an optimal circle using the least squares method, and calculates the center coordinates (a, b) and radius R of the fitted circle;

[0046] The shrinking unit receives the scaling factor P set by the user, and based on the center coordinates (a, b), radius R and scaling factor P, it radially shrinks each original data point (xi, yi) along the direction pointing to the center of the circle, generating and outputting a new set of transformed data points.

[0047] A second aspect of this invention discloses a display system for real-time data on tool machining status, the display system comprising:

[0048] Memory containing executable program code;

[0049] A processor coupled to the memory;

[0050] The processor calls the executable program code stored in the memory to execute the above-described method for displaying real-time data on tool machining status.

[0051] The present invention proposes a method and system for displaying real-time data on tool processing status. The advantages of this method are as follows: By real-time and stable monitoring of the tool holder process signals, the acquired data is fitted and optimized for display within a polar graph coordinate system. Interaction is achieved by adjusting the scale using a scaling factor, which the user can adjust independently. This greatly amplifies and highlights the characteristics of the tool, allowing the user to make a preliminary judgment on the processing status and tool wear based on the polar graph. Simultaneously, the data is presented in a scattered format on the polar graph, and its changes match the real-time processing status. The data presentation delay is low, and continuous monitoring of the tool holder's wear and operating status can extend the service life of the tool and tool holder, reducing replacement frequency and costs. Attached Figure Description

[0052] Figure 1 The process of Embodiment 1 of the present invention Figure 1 ;

[0053] Figure 2 The process of Embodiment 1 of the present invention Figure 2 ;

[0054] Figure 3 This is a polar diagram of the three-flute end mill of the present invention;

[0055] Figure 4 This is a schematic diagram of the test model for the data fitting effect of the present invention;

[0056] Figure 5 This is a diagram showing the actual display effect of the three-flute end mill during end milling according to the present invention;

[0057] Figure 6 This is a diagram showing the actual display effect of the three-flute end mill during side milling according to the present invention;

[0058] Figure 7 This is a schematic diagram of tool wear according to the present invention;

[0059] Figure 8 This is a schematic diagram of the actual state of the cutting tool of the present invention;

[0060] Figure 9 This is a schematic diagram of the optimized fitting state of the present invention;

[0061] Figure 10 This is a schematic diagram of the tool holder structure of the present invention;

[0062] Figure 11 This is a schematic diagram of the strain gauge arrangement structure of the present invention;

[0063] Figure 12 This is a schematic diagram of the full-bridge circuit structure of the present invention;

[0064] Figure 13 This is a structural block diagram of Embodiment 2 of the present invention;

[0065] Figure 14 This is a structural block diagram of Embodiment 3 of the present invention. Detailed Implementation

[0066] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0067] It should be noted that the terms "first," "second," "third," "fourth," etc., used in the specification and claims of this invention are used to distinguish different objects, not to describe a specific order. The terms "comprising" and "having," and any variations thereof, in the embodiments of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to these processes, methods, products, or devices.

[0068] Example 1

[0069] Reference Figure 1 , Figure 2 As one embodiment of the present invention, a method for displaying real-time data of tool machining status is disclosed, specifically the display method including:

[0070] S1. Receive the tool process quantity signal collected and transmitted by the monitoring module, wherein the process quantity signal includes at least the transverse bending moment and the tangential bending moment;

[0071] As an optional implementation, the monitoring module described in this embodiment of the invention may include strain gauges, acquisition sensors, batteries, and a transmitting module. The transverse bending moment and tangential bending moment are acquired by strain gauges distributed along the cross-section of the tool holder. During the processing, the acquisition sensor, based on the measurement circuit, will output a corresponding voltage signal. The wireless receiver connected to the host computer will receive the acquisition signal from the transmitter and transmit the data to the analysis module in the host computer software to achieve synchronous high-frequency stable display.

[0072] S2. According to the user's instructions, the transverse bending moment and tangential bending moment data in the process quantity signal are used as two-dimensional coordinate points (xi, yi) and displayed in the form of scattered points in the polar coordinate graph;

[0073] As an optional implementation, in this embodiment of the invention, the user can display the monitored process quantity signals on a pole figure as needed. The signal points will be presented in the form of scattered points. Of course, the transverse bending moment and tangential bending moment mentioned in this embodiment are force values, and the specific effects are as follows: Figure 3 The test tool corresponding to this figure is a three-flute end mill;

[0074] S3. Based on the set of two-dimensional coordinate points, fit an optimal circle using the least squares method, and calculate the center coordinates O(a, b) and radius R of the fitted circle;

[0075] As an optional implementation, in this embodiment of the invention, taking the transverse bending moment as the X-axis and the tangential bending moment as the Y-axis as an example, based on the coordinates (xi, yi) corresponding to them in the polar figure, when fitting the optimal circle, (a, b) is the center coordinate 0 and R is the radius of the circle. An optimal circle is fitted by the least squares method. The basic principle is to find the best function match of the data by minimizing the sum of squares of the errors.

[0076] S4. Receive the scaling factor P set by the user, and based on the center coordinates (a, b), radius R and scaling factor P, radially shrink each original data point (xi, yi) along the direction pointing to the center of the circle to generate and output a new set of transformed data points.

[0077] As an optional implementation, in this embodiment of the invention, based on the fitted center and radius, the original points can be shrunk and translated along their respective directions toward the center by a specified percentage, and finally the coordinate set of the transformed new points is returned. This specified percentage is the scaling factor P, which can be set by the user as needed. The data of the lateral force of the lateral bending moment and the lateral force of the tangential bending moment are post-processed and analyzed. The real-time topography of the pole figure is used as a feature signal for the user to refer to, so as to intuitively inform the user of the real-time processing status and remind the user in abnormal situations.

[0078] In this invention, by real-time and stable monitoring of the process signals of the tool holder, the acquired data is fitted and the original data can be displayed and optimized within the pole graph coordinates. The scale factor can be adjusted to achieve interaction, which can be adjusted by the user. This greatly amplifies and highlights the characteristics of the tool. The user can make a preliminary judgment on the machining operation status and tool wear based on the pole graph. At the same time, the data is presented in the form of scattered points in the pole graph, and its changes match the real-time machining status. The data presentation delay is low. Continuous monitoring of the wear and working status of the tool holder can extend the service life of the tool and tool holder, and reduce the replacement frequency and cost.

[0079] In some embodiments, after generating and outputting a new set of transformed data points, the method further includes:

[0080] S5. Based on the transformed data points, update and refresh the scatter plot in the display interface, which is then presented in the host computer software.

[0081] As an optional implementation, the host computer in this embodiment of the invention can be a display screen. The data is presented in the form of scattered points in the pole graph. Its changes match the real-time processing status. The processed data can still be displayed synchronously in real time without any visible delay.

[0082] In some embodiments of the present invention, the process of fitting an optimal circle based on the set of two-dimensional coordinate points using the least squares method and calculating the center coordinates O(a, b) and radius R of the fitted circle includes:

[0083] S31. Let the general equation of a circle be: (x - a)² + (y - b)² = R²;

[0084] S32. Convert the general equation into linear form: x² + y² + Ax + By + C = 0;

[0085] The parameters A, B, C are related to the center coordinates O(a, b) and radius R as follows: A = -2a, B = -2b, C = a² + b² - R²;

[0086] S33. Construct the objective function E(A, B, C) for the sum of squared errors as follows:

[0087]

[0088] Where i ranges from 1 to n, and n is the total number of data points in the set of two-dimensional coordinate points.

[0089] That is, by finding a set of optimal parameters (A,B,C,) such that the sum of squared errors corresponding to all test points (xi,yi) is minimized after being substituted into Eq.(2), the corresponding minimization objective function (E(A,B,C)) is minimized.

[0090] Furthermore, the process of fitting an optimal circle using the least squares method based on the set of two-dimensional coordinate points, and calculating the center coordinates (a, b) and radius R of the fitted circle, also includes:

[0091] S34. In the process of finding the minimum value, it is necessary to calculate the partial derivatives with respect to A, B, and C respectively and set them to zero to obtain:

[0092]

[0093]

[0094]

[0095] S35. Construct a system of three linear equations in terms of A, B, and C based on the partial derivative equations. Solve for A and B using a 2x2 linear system, and then solve for C. The solution method is matrix inversion. The linear system is as follows:

[0096]

[0097] Where M11, M12, and M22 are the coefficients for solving the 2x2 matrix of A and B, and MR1 and MR2 are the vectors on the right side of the linear equation system. Specifically, in this embodiment, M11, M12, M21, M22, as well as MR1 ​​and MR2, are calculated from the data in the set of two-dimensional coordinate points.

[0098] S36. After obtaining the values ​​of A, B, and C, according to the formula a = -A / 2, b = -B / 2, R = The center coordinates O(a, b) and radius R of the fitted circle are calculated.

[0099] As an optional implementation, in this embodiment of the invention, the system of equations obtained from three equations with zero partial derivatives is a system of three linear equations in three variables A, B, and C. In actual solution, the properties of the system of equations can be utilized to decouple them. The usual approach is to solve for A and B from the first two equations, at which point the expressions for A and B will contain C. Then, substitute A and B into the third equation to solve for C. Finally, substitute C back to obtain the final values ​​of A and B, specifically including:

[0100] Solve the above system of linear equations composed of partial derivatives. The solution process includes: decoupling the ternary linear equation system, first solving the bivariate subsystem with respect to parameters A and B, solving the bivariate subsystem to obtain the expressions for A and B, substituting the expressions for A and B into the third equation of the original ternary linear equation system to solve for C, and then substituting the value of C back into the expressions for A and B to obtain the final values ​​of A, B, and C.

[0101] Based on the fitted center and radius R, the original points can be shrunk and translated along their respective directions towards the center by a specified percentage, ultimately returning the coordinate set of the transformed new points. This specified percentage is the scaling factor P, which can be set by the user according to their needs, ranging from 0 to 100%. The specific process is as follows:

[0102] The process of receiving the user-defined scaling factor P, and based on the center coordinates (a, b), radius R, and scaling factor P, radially shrinking each original data point (xi, yi) along the direction pointing to the center of the circle, generates and outputs a new set of transformed data points, including:

[0103] S41. Receive the user-defined scaling factor P, wherein the value of P ranges from 0% to 100%. Of course, in other embodiments, the value of P can also be 0-1, which is not limited here.

[0104] S42. Calculate the absolute shrinkage distance d according to the formula d = R x P, where d is the distance that the original data point (xi, yi) needs to move towards the center of the circle;

[0105] For each original data point (xi, yi), perform the following operations:

[0106] S43. Calculate the vector V from the point to the fitted circle center O(a, b): V = (xi - a, yi - b);

[0107] S44. Calculate the distance r from the point to the fitted circle center O(a, b): ;

[0108] S45, According to the formula = r – d, calculate the new distance after contraction .

[0109] In this invention, the actual collected raw data points (xi, yi) are shrunk towards the fitted circle center coordinates O (-A / 2, -B / 2), and the shrunk distance is equal to the fitted circle radius R = Together with the user-specified shrinkage percentage, i.e., the scaling factor P, the transformed new data point N will be closer to the center of the fitted circle, and its position can be obtained through the scaling vector V.

[0110] Furthermore, S46, if If ≥ 0, then by formula N = O + ( The transformed new data point N is obtained by calculating ( / r) x V;

[0111] like If < 0, then discard the original data point.

[0112] For details, please refer to Figure 4 The diagram shows a test model for the data fitting effect, in which... Figure 4 The blue area represents the original point, and the red area represents the transformed point.

[0113] Actual test examples:

[0114] In actual experiments, end milling tests were conducted on aluminum alloys using a three-flute end mill. The test parameters were: rotational speed of 8904 rpm, feed rate of 3205 mm / min, linear speed of 280 mm / min, and cutting depth per flute of 0.12. Figure 5 For the actual display effect, the original data (lateral bending moment is X, tangential bending moment is Y) points are black scattered points, while the points after display optimization are gray scattered points.

[0115] Similarly, a side milling test was conducted on aluminum alloy using a three-flute end mill. The test parameters were: spindle speed of 9540 rpm, feed rate of 4007 mm / min, linear speed of 300 mm / min, and cutting depth per flute of 0.14. Figure 5 The actual display effect is shown using a three-flute end mill for end milling. The left side shows the display state with a scale factor of 80%; the right side shows the display state with a scale factor of 100%. The original data (lateral bending moment is X, tangential bending moment is Y) points are black scattered dots, while the points after display optimization are gray scattered dots.

[0116] It can be observed that after optimization, the three blade angles become very sharp, and this feature is greatly amplified and salienced. Figure 6 The effect is a scale factor of 100%, which is a three-flute end mill - side milling; the left side shows the display state with a scale factor of 50%; the right side shows the display state with a scale factor of 100%, and its features become more obvious. In actual use, users can set the scale factor themselves to determine the desired display effect.

[0117] It should be noted that the data is presented in the form of scattered points in the pole graph, and its changes are matched with the real-time processing status, with a data presentation delay of less than one second.

[0118] Users can make a preliminary judgment on the machining operation status and tool wear based on the pole graph. When there is an abnormality in the operation, the real-time scatter points will change from solid circles in the normal state to hollow triangles.

[0119] Alternatively, a chipped cutting edge indicates that the tool holder is misaligned, the tool is worn, or the set process parameters are incompatible. In this case, the user needs to check the installation and the condition of the tool wear, and repair any problems promptly. A diagram illustrating tool wear is shown below. Figure 7 It can be observed that during the wear-based tool test, the position of the inner cutting edge in the image is asymmetrically distributed and the shape of the cutting edge is not clear. The morphology of the tool used was also photographed subsequently, such as... Figure 8 As shown, the tool has indeed worn. If the problem isn't with the tool, then adjusting the process parameters is necessary. After adjustment, continue the experiment; if the problem returns to normal, continue the experiment.

[0120] When display optimization is selected, the newly transformed gray scatter points can also indicate the tool wear / breakage condition, and the center position of the fitted circle in the newly transformed graph will deviate from the absolute zero point. For example... Figure 9 As shown, the optimized gray area clearly lacks the characteristic of a single cutting edge, and the center of the fitted circle of the new transformation point is significantly deviated from the absolute zero point, effectively indicating to the user that the tool has broken, thus assisting the machining and production process.

[0121] In some embodiments, after receiving the tool process quantity signal acquired and transmitted by the monitoring module, the present invention further includes:

[0122] The process quantity signal is displayed in real time in a display format selected by the user, wherein the display format includes one or more of digital instruments, scatter plots, line graphs or bar charts.

[0123] Furthermore, in this embodiment, the process quantity signals are acquired by a sensing module, which is mounted on the tool holder and used to monitor the pressure, torque, lateral bending moment and tangential bending moment during the tool machining process; the sensing module internally uses a full-bridge circuit composed of strain gauges to convert the above physical quantities into electrical signals.

[0124] In some embodiments of the present invention, the core hardware component can be integrated into or mounted on various rotary or non-rotary cutting tools. Specifically, this hardware solution is suitable for modifying traditional standard machining tool holders (such as common BT, SK, ER, HSK, etc.). The machining tool is not limited and can be replaced with other types of tools or cutting tools such as milling cutters, drills, taps, and stir bar welding heads, depending on the clamping size of the tool holder. The core modification scheme lies in adding a physical structure for accommodating sensing elements at a specific location on the cutting tool or tool holder. For example, a strain groove 1 designed for a strain gauge, such as... Figure 10 As shown, the specific modification schemes for different types of cutting tools are consistent in principle, and will not be elaborated here.

[0125] To achieve multi-dimensional monitoring of the machining process, this embodiment uses strain gauges as the core sensing element. Multiple strain gauges are precisely arranged at different positions on the cross-section of the tool holder or tool to sense different physical quantities. The specific layout is as follows: Figure 11 As shown:

[0126] Pressure / axial force: Measured by strain gauge sets P1 and P2.

[0127] Torque: Measured by strain gauges P3 and P4.

[0128] Lateral bending moment: measured by strain gauges P7 and P8.

[0129] Tangential bending moment: measured by strain gauges P5 and P6.

[0130] This spatial layout allows for precise decoupling and independent acquisition of key mechanical parameters during the manufacturing process.

[0131] Corresponding to the above-mentioned strain gauges, this scheme uses a full-bridge circuit for signal conditioning, and its specific bridge configuration is as follows: Figure 12 The full-bridge circuit shown includes a power input terminal Uin and a signal output terminal Uout. The advantages of using a full-bridge circuit are: it can amplify small mechanical strain (resistance change) into a significant voltage output signal, effectively compensate for common-mode interference such as temperature changes, ensure the stability and accuracy of measurement results, and provide more reliable signals in complex machining electromagnetic environments.

[0132] The strain gauge pins are reliably connected to the subsequent data acquisition sensors via welding or other methods. It should be noted that the specific connection process can be flexibly selected based on actual working conditions and ease of operation; this invention does not impose any limitations on it.

[0133] During machining, the cutting force exerted on the tool causes microscopic mechanical deformation in the area where the strain gauge is mounted. This deformation causes a corresponding change in the resistance value of the strain gauge. Based on the principle of a full-bridge circuit, the resistance change is converted in real time into an analog voltage signal (Uout) proportional to the measured physical quantity (such as force or torque).

[0134] The voltage signal is acquired at high frequency by a monitoring module integrated on the cutting tool. This module is powered by a built-in battery, ensuring its independent operation during rotation or movement. After preliminary processing within the module, such as amplification, filtering, and analog-to-digital conversion, the acquired signal is packaged and transmitted via a wireless transmitter. A wireless receiver located on the host computer is responsible for receiving these data packets and transmitting them to the host computer software in real time.

[0135] After receiving the data, the built-in analysis module of the host computer software unpacks, parses, and performs real-time calculations. Finally, it displays the status information such as pressure, torque, lateral bending moment, and tangential bending moment during the processing in a synchronous, high-frequency, and stable manner in the form of numbers and charts. This is sufficient to capture the high-frequency dynamic characteristics during the processing and provide sufficient data support for status monitoring and fault diagnosis.

[0136] It is important to emphasize that although the above embodiments use strain gauges as an example, the core idea of ​​this invention lies in identifying the lateral force exerted on the tool or the bending moment and vibration caused by it. Therefore, the implementation of the sensing element is not limited to strain gauges. Any other type of sensor or sensing technology that can achieve the same function should be considered as an equivalent alternative covered by the scope of protection of this invention. For example, accelerometers, screen-printed circuits, or thin-film sensors can be used as alternatives to strain gauges, achieving strain measurement in a thinner and more easily integrated manner. These alternatives aim to achieve the same technical objective as this solution—namely, to acquire key physical quantities reflecting the tool's machining state in real time and accurately, and ultimately apply them to the aforementioned data display method.

[0137] Example 2

[0138] Please see Figure 13 , Figure 13 This invention discloses a real-time data display system for tool machining status, the display system comprising:

[0139] The receiving unit 201 displays the tool process quantity signals collected and transmitted by the monitoring module, which include at least transverse bending moment and tangential bending moment.

[0140] As an optional implementation, the monitoring module described in this embodiment of the invention may include strain gauges, acquisition sensors, batteries, and a transmitting module. The transverse bending moment and tangential bending moment are acquired by strain gauges distributed along the cross-section of the tool holder. During the processing, the acquisition sensor, based on the measurement circuit, will output a corresponding voltage signal. The wireless receiver connected to the host computer will receive the acquisition signal from the transmitter and transmit the data to the analysis module in the host computer software to achieve synchronous high-frequency stable display.

[0141] The generation unit 202 and the display system, according to user instructions, use the transverse bending moment and tangential bending moment data in the process quantity signal as two-dimensional coordinate points (xi, yi) and display them in the form of scattered points on the polar coordinate graph;

[0142] As an optional implementation, in this embodiment of the invention, the user can display the monitored process quantity signals in the pole figure as needed. The signal points will be presented in the form of scattered points. Of course, the transverse bending moment and tangential bending moment mentioned in this embodiment are force values.

[0143] Fitting unit 203 displays that the system fits an optimal circle based on the set of two-dimensional coordinate points using the least squares method, and calculates the center coordinates (a, b) and radius R of the fitted circle;

[0144] As an optional implementation, in this embodiment of the invention, taking the transverse bending moment as the X-axis and the tangential bending moment as the Y-axis as an example, based on the coordinates (xi, yi) corresponding to them in the polar figure, when fitting the optimal circle, (a, b) is the center coordinate 0 and R is the radius of the circle. An optimal circle is fitted by the least squares method. The basic principle is to find the best function match of the data by minimizing the sum of squares of the errors.

[0145] The shrinking unit 204 displays that the system receives the scaling factor P set by the user, and based on the center coordinates (a, b), radius R and scaling factor P, it radially shrinks each original data point (xi, yi) along the direction pointing to the center of the circle, generating and outputting a new set of transformed data points.

[0146] As an optional implementation, in this embodiment of the invention, based on the fitted center and radius, the original points can be shrunk and translated along their respective directions toward the center by a specified percentage, and finally the coordinate set of the transformed new points is returned. This specified percentage is the scaling factor P, which can be set by the user as needed. The data of the lateral force of the lateral bending moment and the lateral force of the tangential bending moment are post-processed and analyzed. The real-time topography of the pole figure is used as a feature signal for the user to refer to, so as to intuitively inform the user of the real-time processing status and remind the user in abnormal situations.

[0147] Of course, in some embodiments, the system described in this invention further includes:

[0148] The display unit 205 updates and refreshes the scatter plot in the display interface based on the transformed data points, and the display interface is presented in the host computer software.

[0149] As an optional implementation, the host computer in this embodiment of the invention can be a display screen. The data is presented in the form of scattered points in the pole graph. Its changes match the real-time processing status. The processed data can still be displayed synchronously in real time without any visible delay.

[0150] Example 3

[0151] Please see Figure 14 , Figure 14 This is a schematic diagram of another display system disclosed in an embodiment of the present invention, the display system comprising:

[0152] Memory 301 storing executable program code;

[0153] Processor 302 coupled to the memory 301;

[0154] The processor 302 calls the executable program code stored in the memory 301 to execute the above-described method for displaying real-time data on tool machining status.

[0155] This invention discloses a computer-readable storage medium storing a computer program that causes a computer to execute the above-described method for displaying real-time data on tool machining status.

[0156] This invention also discloses a computer program product, wherein when the computer program product is run on a computer, the computer performs some or all of the steps of the methods described in the above method embodiments.

[0157] Those skilled in the art will understand that all or part of the steps in the various methods of the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, including read-only memory (ROM), random access memory (RAM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), one-time programmable read-only memory (OTPROM), electrically-Erasable Programmable Read-Only Memory (EEPROM), compactdisc read-only memory (CD-ROM) or other optical disc storage, disk storage, magnetic tape storage, or any other computer-readable medium capable of carrying or storing data.

[0158] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A display method of real-time data of a machining state of a tool, characterized by, Comprising: receiving tool process signals collected and transmitted by a monitoring module, the process signals including at least lateral bending moment and tangential bending moment; according to user instructions, taking the lateral bending moment and tangential bending moment data in the process signals as two-dimensional coordinate points (xi, yi), and displaying them in the form of scattered points in a polar coordinate graph; based on the set of two-dimensional coordinate points, fitting an optimal circle by least squares method, and calculating the center coordinates O (a, b) and radius R of the fitted circle; receiving a user-set scaling factor P, and based on the center coordinates (a, b), radius R and scaling factor P, radially contracting each original data point (xi, yi) in the direction pointing to the center of the circle to generate and output a new set of transformed data points.

2. The method of claim 1, wherein: After generating and outputting a new set of transformed data points, the method further comprises: updating and refreshing the scattered point graph in the display interface according to the transformed data points, the display interface being presented in the host computer software.

3. The method of claim 1, wherein: The fitting of an optimal circle by least squares method based on the set of two-dimensional coordinate points, and the calculation of the center coordinates O (a, b) and radius R of the fitted circle, comprises: setting the general equation of the circle as: (x - a)² + (y - b)² = R²; converting the general equation into a linear form: x² + y² + Ax + By + C = 0; wherein the parameters A, B, C are related to the center coordinates (a, b) and radius R as: A = -2a, B = -2b, C = a² + b² - R²; constructing an error sum of squares objective function E(A, B, C) as follows: wherein i is from 1 to n, and n is the total number of data points in the set of two-dimensional coordinate points.

4. The method of claim 3, wherein: The fitting of an optimal circle by least squares method based on the set of two-dimensional coordinate points, and the calculation of the center coordinates (a, b) and radius R of the fitted circle, further comprises: solving the partial derivatives with respect to A, B and C in the minimization process and setting them equal to zero to obtain: constructing a 3-element linear equation set with respect to A, B and C according to the partial derivative equations, solving A and B by a 2x2 linear system, and then solving C, the solving method being matrix inversion, and the linear system being: wherein M11, M12, M22 are the coefficients of the 2x2 matrix for solving A and B, and MR1, MR2 are the vectors on the right side of the linear equation set; When the values of A, B and C are found, the center of the fitted circle O(a, b) and the radius R are calculated according to the formulas a = -A / 2, b = -B / 2, R = C / 2. The center of the fitted circle O(a, b) and the radius R are calculated.

5. The method of claim 1, wherein: The receiving of a user-set scaling factor P, and the radially contracting of each original data point (xi, yi) in the direction pointing to the center of the circle based on the center coordinates (a, b), radius R and scaling factor P to generate and output a new set of transformed data points, comprises: receiving a user-set scaling factor P, wherein the value range of P is 0% to 100%; calculating the absolute contraction distance d according to the formula d = R x P, the d being the distance that the original data point (xi, yi) needs to move towards the center of the circle; for each original data point (xi, yi), performing the following operations: Calculate the vector V of this point to the fitted circle center O(a, b): V = (xi - a, yi - b); The distance r of this point to the center of the fitted circle O(a, b) is calculated: ; According to the formula = r - d, the new distance after contraction is calculated .

6. The method of claim 5, wherein: like If ≥ 0, then by formula N = O + ( The transformed new data point N is obtained by calculating ( / r) x V; If < 0, then the original data point is discarded.

7. The method of claim 1, wherein: The receiving tool process signal collected and transmitted by the monitoring module further comprises; The process signal is displayed in real time in a display form selected by a user, wherein the display form comprises one or more of a digital instrument, a scatter plot, a curve graph or a column chart.

8. The method of claim 1, wherein: The process signal is collected by a sensing module installed on a tool holder for monitoring pressure, torque, transverse bending moment and tangential bending moment in a tool machining process; the sensing module internally uses a full-bridge circuit composed of strain gauges to convert the above physical quantities into electrical signals.

9. A display system for real-time data of a machining state of a tool, characterized in that The display system comprises: A receiving unit that receives tool process signals collected and transmitted by a monitoring module, wherein the process signals at least include transverse bending moment and tangential bending moment; A generating unit that, according to a user instruction, takes the transverse bending moment and tangential bending moment data in the process signals as two-dimensional coordinate points (xi, yi) and displays them in a scatter form in a polar coordinate graph; A fitting unit that, based on the two-dimensional coordinate point set, fits an optimal circle through a least square method and calculates the center coordinates (a, b) and radius R of the fitted circle; A contracting unit that receives a scale factor P set by a user and, based on the center coordinates (a, b), radius R and scale factor P, contracts each original data point (xi, yi) in a radial direction along its direction to the center to generate and output a new set of transformed data points.

10. A display system for real-time data of a machining state of a tool, characterized in that The display system comprises: A memory that stores executable program codes; A processor coupled with the memory; The processor calls the executable program codes stored in the memory to execute the display method of real-time data of a tool machining state according to any one of claims 1-8.

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