Vibration reduction cutter environment state monitoring system and method

Abstract

The invention belongs to the field of intelligent manufacturing, and particularly relates to a vibration reduction tool environment state monitoring system and method. The invention aims to provide the environment state monitoring system and method for the vibration reduction cutter, and the system and method can monitor the temperature and the angle in real time, and adjust the parameters of a vibration absorber according to an acquired acceleration signal, so as to ensure a good cutter machining environment and improve the cutter machining precision. According to the technical scheme, the vibration reduction tool environment state monitoring system comprises a tool, a signal acquisition module and an upper computer comprising a signal analysis module and an interface display module; the device is characterized by further comprising a vibration absorber mounted on the cutter; the signal acquisition module comprises a temperature sensor, an acceleration sensor and an angle sensor which are used for acquiring cutter environment signals, and further comprises a constant current adapter and a temperature transmitter which are used for signal conditioning, and a data acquisition unit used for signal acquisition and storage.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of intelligent manufacturing, and particularly relates to a vibration-reducing tool environment state monitoring system and method. BACKGROUND

[0002] In intelligent manufacturing, online state monitoring of tools is a key technology for realizing tool full-life monitoring and preventing tool damage, and is also a necessary prerequisite for further improving workpiece machining precision and machining quality. A machining process often accompanies a large amount of cutting physical information, such as sound, power, cutting force, temperature, etc. Real-time perception of cutting signals and monitoring of tool machining states are core links for guaranteeing efficient production, equipment safety and product quality, and are also indispensable components of an intelligent manufacturing system.

[0003] A tool state monitoring system generally adopts a direct method or an indirect method to collect cutting state information. The direct method is generally offline monitoring, such as directly evaluating tool wear through measurement means during a non-cutting working period. Specific methods include optical measurement technology, radioactive detection, workpiece and tool contact resistance measurement, workpiece size precision measurement, etc. This method has low cost and reliable measurement results, but has two obvious shortcomings: first, the production equipment needs to be shut down for tool or workpiece detection, which will damage the continuity of production; second, the detection interval is long and cannot cope with sudden failures.

[0004] The indirect method is to use sensors to monitor signals closely related to the cutting state in real time. The state of the tool is indirectly obtained by monitoring the changes in the cutting signals. The advantages of this method are: first, it can monitor the cutting state in real time and can be widely applied to various machining processes; second, it has little or no impact on the machining process. However, the traditional method often relies on a single signal source or intermittent detection, making it difficult to obtain tool state information in real time. This method has the problems of insufficient data coverage and low parameter correlation.

[0005] The present situation urgently needs a vibration-reducing tool environment state monitoring system and method to comprehensively collect and comprehensively analyze tool environment state data in order to take appropriate measures to improve tool machining precision and tool life. SUMMARY

[0006] The purpose of the present application is to overcome the shortcomings in the background art, and to provide a vibration-reducing tool environment state monitoring system and method that can monitor temperature and angle in real time, and adjust the parameters of the vibration absorber according to the collected acceleration signals to ensure a good tool machining environment and improve tool machining precision.

[0007] The technical solution of the present application is:

[0008] A kind of damping tool environment state monitoring system, including tool, signal acquisition module and the host computer comprising signal analysis module and interface display module;Its characterized in that: still include vibration absorber installed on tool;

[0009] The signal acquisition module includes temperature sensor, acceleration sensor and angle sensor for collecting tool environment signal, also includes constant-current adapter and temperature transmitter for signal conditioning and data collector for signal acquisition and preservation;

[0010] The temperature sensor and acceleration sensor are installed in the front end of tool, and are connected to the constant-current adapter and temperature transmitter by wire embedded in tool respectively, then are connected to the data collector in parallel;The angle sensor is installed on the rear end outer wall of tool, and is connected to the data collector by wire;The output end of data collector is connected to the host computer.

[0011] The front end of tool is provided with inner cavity, and the temperature sensor and acceleration sensor are installed in the inner cavity.

[0012] The wire of temperature sensor and the wire of acceleration sensor are laid in cooling liquid channel and extend from the rear end of tool;Or are laid in the pipe hole that communicates inner cavity and penetrates the rear end of tool, and then extend from the rear end of tool.

[0013] The inner cavity is blind hole with orifice closed.

[0014] The front half of tool is provided with cavity, and the vibration absorber is installed in the cavity.

[0015] A kind of damping tool environment state monitoring method, according to the following steps:

[0016] (1) the charge signal collected from tool by acceleration sensor is amplified to standard voltage signal by constant-current adapter and then transmitted to signal collector;

[0017] The thermocouple signal of temperature sensor is transmitted to signal collector after being processed by temperature transmitter from the signal collected from tool;

[0018] The voltage signal output by angle sensor is directly transmitted to signal collector;

[0019] (2) data collector collects signal in real time, and saves data;Then all signals collected are transmitted to host computer;

[0020] (3) the host computer converts temperature signal voltage value into corresponding actual temperature, converts angle signal voltage value into corresponding actual rotation angle, converts vibration signal voltage value into corresponding vibration acceleration value, and simultaneously converts and calculates vibration frequency signal of tool from vibration acceleration signal;

[0021] (4) The host computer displays the processed temperature, angle and acceleration signals through the display device; the temperature display part contains the actual temperature and the set temperature, and when the actual temperature is higher than the set temperature, the alarm light flashes; the acceleration display part also contains the tool frequency signal calculated by the Fourier transform of the acceleration signal, thereby providing a reference for adjusting the parameters of the vibration absorber.

[0022] The processing of the temperature transmitter in the step is: after isolation and amplification of the received signal, it is converted into a direct current signal linear with temperature.

[0023] The processing analysis of the host computer in the step (1) includes:

[0024] The signal analysis module converts the temperature signal voltage value into the corresponding actual temperature, converts the angle signal voltage value into the corresponding actual rotation angle, converts the vibration signal voltage value into the corresponding vibration acceleration value, and calculates the vibration frequency of the tool by Fourier transform of the acceleration signal.

[0025] The interface display module of the host computer displays the actual temperature, actual rotation angle, vibration acceleration value and vibration frequency; the display of the actual temperature contains the actual temperature and the set temperature, and when the actual temperature is higher than the set temperature, the alarm light of the host computer flashes. The display of the vibration acceleration contains a graphical selection box for selecting the display of the acceleration time domain graph, the tool vibration frequency graph or other processed vibration signals; the tool vibration frequency graph provides a reference for adjusting the parameters of the vibration absorber.

[0026] The beneficial effects of the present application are:

[0027] (1) During processing, the tool and the workpiece rub violently to generate a large amount of heat, and the cutting heat not only affects the surface roughness of the workpiece, but also causes the temperature of the tool to rise, reducing the service life of the tool. By installing a temperature sensor at the front end of the tool, the tool temperature is monitored in real time, and an alarm function is provided to ensure that the tool temperature does not become too high during processing, prolonging the service life of the tool and improving the processing stability of the workpiece.

[0028] (2) By installing an angle sensor at the end of the tool, the horizontal rotation angle of the tool is monitored in real time, which can ensure that the blade enters the cutting in a horizontal state and improve the processing accuracy of the workpiece.

[0029] (3) By installing an acceleration sensor at the front end of the tool, the intensity of cutting vibration is monitored in real time, and when the vibration is detected to be too intense, the feed rate can be reduced in time to prevent the processing accuracy from decreasing. In addition, the vibration frequency of the tool is calculated by Fourier transform, which facilitates the timely adjustment of the parameters of the vibration absorber to improve its vibration absorption effect and ensure that the tool is in a good processing environment. BRIEF DESCRIPTION OF DRAWINGS

[0030] Figure 1 is a simplified block diagram of the vibration-damping tool environment state monitoring system of the present application.

[0031] Reference signs:

[0032] Temperature sensor 1, acceleration sensor 2, vibration absorber 3, tool 4, angle sensor 5, constant current adapter 6, temperature transmitter 7, data collector 8, host computer 9, acceleration signal 10, angle signal 11, temperature signal 12. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical scheme and advantages of the present application more clear, the present application is further described in detail below in combination with the drawings and examples. It should be understood that the specific examples described herein are only used to explain the present application and do not limit the present application.

[0034] Figure 1 The vibration-damping tool environment state monitoring system shown includes a temperature sensor 1, an acceleration sensor 2, a vibration absorber 3, a tool 4, an angle sensor 5, a constant current adapter 6, a temperature transmitter 7, a data collector 8 and a host computer 9 (preferably a LabVIEW host computer).

[0035] The front end (i.e. the tool head part) of the tool is provided with an inner cavity, and the acceleration sensor 2 and the temperature sensor 1 are installed in the inner cavity to prevent the cutting fluid and the cutting chips from splashing and damaging the sensors during cutting; since the tool 4 is hollow inside to form a cooling liquid channel for passing cooling liquid, the rear end of the tool 4 is a cooling liquid inlet and the tool head part is a cooling liquid outlet, so it is necessary to separate the cooling liquid and the sensors to prevent the sensors from being damaged due to the impact of the cooling liquid.

[0036] The sensors are each provided with a wire, so it is also necessary to lay the sensor wires on the tool 4 to transmit the sensor electrical signals out through the wires; there are two ways to lay the sensor wires, one is to lay them in the cooling liquid channel, the sensor wires enter the cooling liquid channel from a branch drilled in the wall of the inner cavity, and then extend out of the rear end of the tool 4, but sealing work (such as applying sealing glue) needs to be done at the branch part to ensure that the cooling liquid cannot enter the inner cavity; the second way is to drill a tube hole on the tool 4 that communicates with the inner cavity and penetrates through the rear end of the tool, for installing the wires of the sensors, and the overhanging end of the wires extends out of the rear end of the tool 4; since the tube hole is separated from the cooling liquid channel, the wires will not be affected by the cooling liquid. In order to reduce the installation difficulty, the angle sensor 5 is designed to be installed on the outer wall of the rear end of the tool 4.

[0037] As a recommendation, the inner cavity is a blind hole with a hole opening closed; the manufacturing method is to first make a blind hole, and then weld (preferably tin solder) the hole opening of the blind hole after the sensor is placed in the blind hole.

[0038] The wire transmitting the acceleration sensor signal extends from behind the tool 4 and is connected to the constant current adapter 6; the constant current adapter 6 amplifies the charge signal output by the acceleration sensor 2 into a standard voltage signal and then transmits the signal to the data collector 8. Another wire transmitting the temperature sensor signal extends from behind the tool 4 and is connected to the temperature transmitter 7; the temperature transmitter 7 converts the thermocouple signal output by the temperature sensor 1 into a direct current signal linearly related to temperature after isolation amplification and then transmits the signal to the signal collector 8. The angle sensor 5 also transmits the collected angular velocity voltage signal to the signal collector 8 through a signal transmitting wire. The signal collector 8 collects the three input signals in real time, saves the signal data and transmits all the signals to the host computer 9 (prior art).

[0039] The interface display module of the host computer 9 displays the temperature, angle, acceleration and menu bar respectively.

[0040] The temperature display part includes the actual temperature, set temperature and alarm light. When the actual temperature is higher than the set temperature, the host computer alarm light flashes. The acceleration display part includes a graphical selection box for selecting the display of acceleration time domain graph, tool vibration frequency graph or other processed vibration signals.

[0041] The front half of the tool 4 is provided with a vibration absorber 3, and the vibration absorber can be adjusted according to the tool vibration frequency graph.

[0042] The tool environment state monitoring method of the vibration damping tool environment state monitoring system is performed according to the following steps:

[0043] 1. The charge signal collected by the acceleration sensor 2 from the tool is amplified by the constant current adapter 6 and then transmitted to the signal collector 8;

[0044] The thermocouple signal collected by the temperature sensor 1 from the tool is processed by the temperature transmitter 7 and then transmitted to the signal collector 8;

[0045] The voltage signal output by the angle sensor 5 is directly transmitted to the signal collector 8;

[0046] 2. The data collector 8 collects signals in real time and saves data; then transmits all the collected signals to the host computer 9;

[0047] 3. The host computer 9 converts the temperature signal voltage value into the corresponding actual temperature, converts the angle signal voltage value into the corresponding actual angle, converts the vibration signal voltage value into the corresponding vibration acceleration value, and simultaneously converts and calculates the vibration acceleration signal to obtain the vibration frequency signal of the tool;

[0048] 4, The host computer 9 displays the processed temperature signal 12, angle signal 11 and acceleration signal 10 through the display screen (or other display device) of the host computer; the temperature display part contains the actual temperature and the set temperature, and when the actual temperature is higher than the set temperature, the alarm light flashes; the acceleration display part also contains the tool frequency signal calculated by the Fourier transform of the acceleration signal, thereby providing a reference for adjusting the parameters of the vibration absorber 3.

[0049] The working principle of the present application is as follows:

[0050] The tool environment state monitoring system converts various environmental signals into voltage signals, which are collected by the data collector 8 after processing and transmitted to the host computer 9. The charge signal output by the acceleration sensor 2 is amplified by the constant current adapter 6 and then transmitted to the signal collector 8, the signal output by the temperature sensor 1 is processed by the temperature transmitter 7 and then transmitted to the signal collector 8, the voltage signal output by the angle sensor 5 is directly transmitted to the signal collector 8, the data collector 8 collects signals in real time and saves data, the signal collector 8 transmits all collected signals to the host computer 9, the host computer 9 converts the voltage value of the temperature signal into the corresponding actual temperature, converts the voltage value of the angle signal into the corresponding actual angle, converts the voltage value of the vibration signal into the corresponding vibration acceleration value, and at the same time, converts and calculates the vibration frequency signal of the tool from the acceleration signal. The host computer 9 displays the processed temperature, angle and acceleration signals. The temperature display part contains the actual temperature and the set temperature, and when the actual temperature is higher than the set temperature, the alarm light flashes. The acceleration display part also contains the tool frequency signal calculated by the Fourier transform of the acceleration signal, which can provide a reference for adjusting the parameters of the vibration absorber 3.

[0051] Finally, it should be noted that the above-mentioned is only a specific embodiment of the present application. Obviously, the present application is not limited to the above-mentioned, but can have many variations. All variations that can be directly derived or inferred from the content disclosed in the present application by those skilled in the art should be considered as the protection scope of the present application.

Claims

1. A vibration-damping tool environmental condition monitoring system, comprising a tool (4), a signal acquisition module, and a host computer (9) including a signal analysis module and an interface display module; characterized in that: It also includes a vibration damper (3) mounted on the cutting tool (4); The signal acquisition module includes a temperature sensor (1), an acceleration sensor (2), and an angle sensor (5) for acquiring tool environment signals, as well as a constant current adapter (6) and a temperature transmitter (7) for signal conditioning, and a data acquisition unit (8) for signal acquisition and storage. The temperature sensor (1) and the acceleration sensor (2) are installed inside the front end of the tool (4) and are connected to the constant current adapter (6) and the temperature transmitter (7) respectively through wires embedded in the tool, and then connected to the data acquisition device in parallel; the angle sensor (5) is installed on the outer wall of the rear end of the tool (4) and is also connected to the data acquisition device (8) through wires; the output end of the data acquisition device (8) is connected to the host computer.

2. The vibration damping tool environmental condition monitoring system according to claim 1, characterized in that: The front end of the cutting tool (4) has an inner cavity, and the temperature sensor (1) and the acceleration sensor (2) are installed in the inner cavity.

3. The vibration damping tool environmental condition monitoring system according to claim 2, characterized in that: The wires of the temperature sensor (1) and the accelerometer (2) are laid in the coolant channel and extend from the rear end of the cutter (4); or laid in a tube hole that connects to the inner cavity and passes through the rear end of the cutter (4) and then extend from the rear end of the cutter (4).

4. The vibration damping tool environmental condition monitoring system according to claim 3, characterized in that: The inner cavity is a blind hole with the opening closed.

5. The vibration damping tool environmental condition monitoring system according to claim 4, characterized in that: The front half of the cutting tool (4) has a cavity, and the vibration absorber (3) is installed in the cavity.

6. The method for monitoring the tool environment condition using the vibration-damping tool environment condition monitoring system as described in claim 1 is performed according to the following steps: (1) The accelerometer (2) collects the charge signal from the tool, which is then amplified into a standard voltage signal by the constant current adapter (6) and transmitted to the signal acquisition unit (8); The thermocouple signal of the temperature sensor (1) is collected from the cutting tool and then processed by the temperature transmitter (7) and transmitted to the signal acquisition unit (8); The voltage signal output by the angle sensor (5) is directly transmitted to the signal acquisition unit (8); (2) The data acquisition unit (8) acquires signals in real time and saves the data; then it transmits all the acquired signals to the host computer (9); (3) The host computer (9) converts the temperature signal voltage value into the corresponding actual temperature, the angle signal voltage value into the corresponding actual rotation angle, and the vibration signal voltage value into the corresponding vibration acceleration value. At the same time, it converts and calculates the vibration acceleration signal to obtain the vibration frequency signal of the tool. (4) The host computer (9) displays the processed and analyzed temperature, angle and acceleration signals through the display device; the temperature display section includes the actual temperature and the set temperature. When the actual temperature is higher than the set temperature, the alarm light flashes; the acceleration display section also includes the tool frequency signal obtained by Fourier transform of the acceleration signal, thereby providing a reference for adjusting the parameters of the vibration absorber (3).

7. The method for monitoring the environmental condition of a cutting tool according to claim 6, characterized in that: The processing of the temperature transmitter (7) in step (1) is as follows: after isolating and amplifying the received signal, it is converted into a DC signal that is linearly related to the temperature.

8. The method for monitoring the environmental condition of a cutting tool according to claim 7, characterized in that: The processing and analysis by the host computer (9) in step (1) includes: The signal analysis module converts the temperature signal voltage value into the corresponding actual temperature, the angle signal voltage value into the corresponding actual rotation angle, and the vibration signal voltage value into the corresponding vibration acceleration value. It then performs a Fourier transform on the acceleration signal to calculate the vibration frequency of the tool.

9. The method for monitoring the environmental condition of a cutting tool according to claim 8, characterized in that: The interface display module of the host computer (9) displays the actual temperature, actual rotation angle, vibration acceleration value and vibration frequency; the actual temperature display includes the actual temperature and the set temperature, and the host computer alarm light flashes when the actual temperature is higher than the set temperature; the vibration acceleration display includes a graphic selection box, which is used to select the display of acceleration time domain graph, tool vibration frequency graph or other processed vibration signal; the tool vibration frequency graph provides a reference for adjusting the parameters of the vibration absorber (3).

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