Automatic monitoring and intelligent early warning method and system for service life of sheave spool

Abstract

The invention discloses an automatic monitoring and intelligent early warning method and system for the service life of a sheave spool. The method comprises the steps that the installation state of a sheave or a spool is detected in real time, and whether a wire cutting machine starts machining or not is determined; when it is detected that the geneva wheel or the spool is installed and the wire cutting machine is started for machining, the use starting time is recorded; when it is detected that the geneva wheel or the spool is detached or the wire cutting machine stops machining, the use end time is recorded; calculating actual use duration according to the use starting time and the use ending time; dynamically calculating the residual life based on a preset standard life parameter and the actual use duration; and when the residual life is lower than a preset early warning threshold value, triggering an early warning prompt. According to the method, whole-course accurate tracing and dynamic management of the service life of the sheave and the spool can be achieved, the remaining service life can be calculated in real time, a prompt is given out in advance when the remaining service life reaches an early warning threshold value, faults such as wire breakage and abrasion caused by overdue use are effectively prevented, non-planned downtime is shortened, the equipment utilization rate is increased, and production continuity and stability are guaranteed.

Description

Technical Field

[0001] This application belongs to the field of consumable management technology for wire EDM equipment, and in particular relates to a method and system for automated monitoring and intelligent early warning of the life of grooved wheel spools. Background Technology

[0002] In the current wire EDM industry, grooved wheels and spools are core consumables, and their lifespan management primarily relies on manual recording. Operators must manually record the installation time each time they replace a grooved wheel or spool, and register the usage duration after use. This method has several problems:

[0003] First, manual recording is easily affected by factors such as operator negligence, unclear handover, or failure to register night shift changes in a timely manner, resulting in missing or incorrect usage time points, making it impossible to accurately trace the actual service life of the grooved wheel or spool.

[0004] Secondly, the lifespan warning mechanism is basically ineffective. Because it relies on manual calculation of the remaining lifespan, there are often cases of overuse. For example, the standard lifespan of a grooved wheel is 100 hours, but it has actually been used for 105 hours but continues to be used because it has not been recorded. This leads to broken cutting lines, excessive wear of the grooved wheel, or even equipment failure, affecting the production schedule.

[0005] Furthermore, data management is fragmented. The lifespan data of grooved wheels and spools from different machines and batches are usually recorded in paper forms or separate information systems, making it difficult to conduct unified aggregation and in-depth analysis, and thus impossible to identify abnormally worn batches or optimize procurement strategies.

[0006] Finally, manual management requires dedicated personnel to record and compile statistics, which is not only costly in terms of manpower but also inefficient, making it difficult to meet the requirements of modern intelligent manufacturing for real-time data, accuracy, and traceability.

[0007] The above analysis shows that there is an urgent need for a method and system that can automate and intelligently manage the lifespan of wheel hubs and spools, in order to improve the reliability of production data, the timeliness of early warning, and management efficiency. Summary of the Invention

[0008] This application provides an automated monitoring and intelligent early warning method and system for the life of Geneva wheel spools, aiming to solve the problems of existing Geneva wheel and spool life management relying on manual recording, which has problems such as recording delays, omissions, early warning failures, data dispersion, and high labor costs.

[0009] To solve at least one of the above-mentioned technical problems, the technical solution adopted in this application is:

[0010] A method for automated monitoring and intelligent early warning of the lifespan of a grooved wheel spool, comprising the following steps:

[0011] Real-time monitoring of the installation status of the grooved wheel or spool and confirmation of whether the wire cutting machine has started processing;

[0012] Record the start time of use when it is detected that the grooved wheel or bob has been installed and the wire cutting machine has started processing.

[0013] When the removal of the grooved wheel or spool is detected, or when the wire cutter stops processing, the end time of use is recorded;

[0014] The actual usage time is calculated based on the start and end times.

[0015] The remaining lifespan is dynamically calculated based on preset standard lifespan parameters and actual usage time.

[0016] An early warning message is triggered when the remaining lifespan is lower than the preset warning threshold.

[0017] Furthermore, the installation status of the grooved wheel or spool is detected by installation detection sensors installed on the grooved wheel mounting position and the spool loading position; the start-up status of the wire cutting machine is detected by a processing start-up sensor installed in the wire cutting machine's electrical control unit.

[0018] Furthermore, the sensor includes at least one of a photoelectric sensor, a pressure sensor, or a proximity switch.

[0019] Furthermore, both the grooved wheel and the spool are equipped with a unique identifier, which is a QR code or an RFID tag.

[0020] Furthermore, the method also includes:

[0021] Establish a relationship between the Geneva or spool identifier and the standard life parameters in the database;

[0022] Update the cumulative usage time and remaining lifespan corresponding to this identifier after each use.

[0023] Furthermore, the start and end times are recorded using a timer, and the trigger condition for the timer is:

[0024] The recording conditions for the start time are: receiving a signal that the groove wheel or spool has been installed and a signal that the wire cutting machine has started processing;

[0025] The conditions for recording the end time are: receiving a signal that the grooved wheel or spool is not installed, or receiving a signal that the wire cutting machine has completed processing and there are no subsequent processing tasks.

[0026] Furthermore, the formula for dynamically calculating the remaining lifetime is as follows:

[0027] Remaining lifespan = Standard lifespan - Cumulative usage time;

[0028] .

[0029] Furthermore, the warning prompts include at least one of the following: audible and visual alarms, display screen prompts, or sending warning information to the MES system.

[0030] Furthermore, it also includes:

[0031] The start time, end time, cumulative duration, and remaining lifespan data for each use are uploaded to the EAP system in real time.

[0032] Data is synchronized to the factory's MES system through the EAP system for production planning optimization and procurement decision support.

[0033] Analyze the wear trends of wheel hubs or spools based on historical lifespan data to identify batches with abnormal wear.

[0034] Adjust procurement strategies or update standard life parameters based on the analysis results.

[0035] An automated monitoring and intelligent early warning system for the life of a grooved wheel spool, used to implement the method described above, includes:

[0036] The sensor group includes an installation detection sensor for detecting whether the grooved wheel or spool is installed in place, and a processing start sensor for detecting whether the wire cutting machine has started processing.

[0037] The data acquisition and processing module is connected to the sensor group and is used to receive sensor signals and trigger timing and record the start and end times of use according to preset logic.

[0038] The life management database is used to store the unique identifier of each groove wheel or spool, the corresponding standard life parameters, the duration of each use, and the calculated remaining life data.

[0039] The early warning interaction module is connected to the lifespan management database and is used to issue an early warning when the remaining lifespan is lower than a threshold, and to provide a human-computer interaction interface.

[0040] The automated monitoring and intelligent early warning method and system for the lifespan of Geneva wheels and spools designed in this application enables precise tracking and dynamic management of the entire lifespan of Geneva wheels and spools. This eliminates the problems of lag, omissions, and errors caused by manual recording, improving the reliability and timeliness of production data. The system calculates the remaining lifespan in real time and provides advance warning when the warning threshold is reached, effectively preventing failures such as wire breakage and wear caused by exceeding the service life, reducing unplanned downtime, and ensuring continuous and stable production. Simultaneously, all lifespan data is centrally stored and supports in-depth analysis, providing data support for identifying abnormal wear and optimizing procurement strategies, thereby reducing consumable costs. Furthermore, automated management replaces manual recording, reducing labor input and operating costs, and driving wire EDM production towards intelligence and digitalization. Attached Figure Description

[0041] Figure 1 This is a flowchart of the early warning method in this application;

[0042] Figure 2 This is a flowchart illustrating the communication transmission judgment process in this application;

[0043] Figure 3 This is a flowchart of the early warning system in this application;

[0044] Figure 4 This is a schematic diagram of the sensor location in this application.

[0045] In the picture:

[0046] 10. Grooved wheel; 11. Install detection sensor one; 20. Bollard; 21. Install detection sensor two; 30. Electrical control unit; 31. Machining start sensor. Detailed Implementation

[0047] The present application will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0048] This embodiment proposes an automated monitoring and intelligent early warning method for the life of a grooved wheel spool, such as... Figure 1 As shown, the steps include:

[0049] S1. Real-time detection of the installation status of the grooved wheel or spool and confirmation of whether the wire cutting machine has started processing.

[0050] like Figure 4 As shown, the installation status of the Geneva wheel 10 or the spool 20 is detected by an installation detection sensor 11 installed on the mounting position of the Geneva wheel 10 and an installation detection sensor 21 installed on the loading position of the spool 20. The installation detection sensor 11 is installed at the bottom of the mounting slot of the Geneva wheel 10, and the installation detection sensor 21 is installed on the bracket of the loading shaft of the spool 20.

[0051] When the grooved wheel 10 or spool 20 is correctly installed, it will physically block the light path of the photoelectric sensor, or be brought close to the proximity switch to detect a metal object, or press the microswitch. The sensor will then generate a voltage level change from OFF to ON, which is interpreted as indicating installation. When removed, the signal resets to not installed. The purpose is to detect whether the grooved wheel 10 or spool 20 is correctly installed in the working position of the wire cutter, such as whether the grooved wheel is fully engaged with the main shaft and the spool is fully inserted into the wire feeder; or whether it is in an installed or removed state.

[0052] Simultaneously, the processing start sensor 31, installed in the wire cutting machine control circuit (i.e., the electronic control unit 30), detects the status signal of the wire cutting machine's start-up processing to determine whether the wire cutting machine has started cutting operations or is in standby, debugging, paused, or stopped state. This confirms the working status of the grooved wheel 10 and the spool 20, preparing for lifespan timing.

[0053] The trigger signal is that after the machining button is pressed, the spindle motor starts, and then the EAP sends a machining start signal. Upon receiving the signal, the machining start sensor 31 begins machining. Simultaneously, unique identifiers, such as QR codes or RFID tags, are affixed to both the grooved wheel and the spool. The installation detection sensor 11, installation detection sensor 21, and machining start sensor 31 employ at least one of the following: photoelectric sensors, pressure sensors, or proximity switches.

[0054] S2. When it is detected that the grooved wheel or spool has been installed and the wire cutting machine has started processing, record the start time of use.

[0055] The data from the installation of detection sensor 11, the installation of detection sensor 21, and the processing start sensor 31 are collected and processed uniformly by the data acquisition module; the data acquisition module is integrated into the PLC controller of the wire cutting machine.

[0056] like Figure 2 As shown, the recording condition for triggering the start time is the receipt of a signal indicating that the grooved wheel or spool has been installed and the signal indicating that the wire cutting machine has started processing. That is, the data acquisition module captures the signal indicating that the grooved wheel 10 has been installed through the installation detection sensor 11 or the signal indicating that the wire groove 20 has been installed through the installation detection sensor 21, and captures the signal indicating that the wire cutting machine has started processing through the processing start sensor 31; when these signals are confirmed as true by the PLC controller, the timer is triggered and recorded as the start time of use of the grooved wheel 10 or spool 20, and the time is accurate to the second.

[0057] At the same time, a relationship is established between the Geneva wheel or spool identifier and the standard life parameters in the database. That is, in the life management database, a unique record file is created for this specific Geneva wheel or spool ID, and the cumulative usage time and remaining life corresponding to the identifier are updated after each use.

[0058] When creating a record file, the system first retrieves the QR code or RFID tag from the existing Geneva wheel 10 / spool 20 in the database. If there is no Geneva wheel 10 / spool 20 currently being recorded, it defaults to associating the ID corresponding to the Geneva wheel 10 / spool 20 of the current wire cutting machine and records the start time. The data acquisition module uploads the received time data to the EAP system and records the start time.

[0059] The QR code or RFID tag on the grooved wheel 10 / spool 20 is a unique ID identifier that is scanned and read by a reader during installation.

[0060] S3. When the removal of the grooved wheel or spool or the stop of the wire cutting machine is detected, record the end time of use.

[0061] The recording conditions for triggering the end time are: receiving a signal that the grooved wheel or spool is not installed, or receiving a signal that the wire cutting machine has completed processing and there are no subsequent processing tasks. That is, when the grooved wheel 10 or spool 20 is removed from its mounting position, the installation detection sensor 11 or installation detection sensor 21 sends an "not installed" signal to the data acquisition module, and the data acquisition module records the current time as the end time of use for the grooved wheel 10 or spool 20 using a timer. Alternatively, when the wire cutting machine stops processing and there are no subsequent processing tasks, a processing completion signal is triggered, and the data acquisition module records the current time as the end time of use for the grooved wheel 10 or spool 20. The data acquisition module then uploads the received time data to the EAP system to record the end time.

[0062] S4. Calculate the actual usage time based on the start and end times.

[0063] The data acquisition module retrieves the standard lifespan (e.g., 100 hours) of the Geneva 10 / spool 20 from the database. The formula for dynamically calculating the remaining lifespan is then:

[0064] Remaining lifespan = Standard lifespan - Cumulative usage time;

[0065] .

[0066] At the same time, update the remaining lifetime in the database.

[0067] S5. Based on preset standard life parameters and actual usage time, dynamically calculate the remaining life; when the remaining life is lower than the preset warning threshold, trigger a warning prompt.

[0068] If the remaining lifespan is less than or equal to the warning threshold, the warning module will immediately output a notification. The warning notification may include at least one of the following: an audible and visual alarm, a display screen notification, or sending a warning message to the MES system.

[0069] This method also includes uploading the start time, end time, cumulative duration, and remaining lifespan data for each use to the EAP system in real time; the EAP system then synchronizes the data to the factory's MES system for production planning optimization and procurement decision support. Simultaneously, it analyzes the wear trends of the wheel or spool based on historical lifespan data to identify abnormal wear batches; and adjusts procurement strategies or updates standard lifespan parameters based on the analysis results.

[0070] An automated monitoring and intelligent early warning system for the life of a grooved wheel spool, as described above, is provided. Figure 4 As shown, it includes:

[0071] The sensor group includes an installation detection sensor for detecting whether the grooved wheel or spool is installed in place, and a processing start sensor for detecting whether the wire cutting machine has started processing.

[0072] The data acquisition and processing module is connected to the sensor group and is used to receive sensor signals and trigger timing and record the start and end times of use according to preset logic.

[0073] The life management database is used to store the unique identifier of each groove wheel or spool, the corresponding standard life parameters, the duration of each use, and the calculated remaining life data.

[0074] The early warning interaction module is connected to the lifespan management database and is used to issue an early warning when the remaining lifespan is lower than a threshold, and to provide a human-computer interaction interface.

[0075] The automated monitoring and intelligent early warning method and system for the lifespan of Geneva wheels and spools designed in this application enables precise tracking and dynamic management of the entire lifespan of Geneva wheels and spools. This eliminates the problems of lag, omissions, and errors caused by manual recording, improving the reliability and timeliness of production data. The system calculates the remaining lifespan in real time and provides advance warning when the warning threshold is reached, effectively preventing failures such as wire breakage and wear caused by exceeding the service life, reducing unplanned downtime, and ensuring continuous and stable production. Simultaneously, all lifespan data is centrally stored and supports in-depth analysis, providing data support for identifying abnormal wear and optimizing procurement strategies, thereby reducing consumable costs. Furthermore, automated management replaces manual recording, reducing labor input and operating costs, and driving wire EDM production towards intelligence and digitalization.

[0076] The embodiments of this application have been described in detail above. These descriptions are merely preferred embodiments and should not be construed as limiting the scope of this application. All equivalent variations and modifications made within the scope of this application should still fall within the patent coverage of this application.

Claims

1. A method for automated monitoring and intelligent early warning of the lifespan of a grooved wheel spool, characterized by the following steps: include: Real-time monitoring of the installation status of the grooved wheel or spool and confirmation of whether the wire cutting machine has started processing; Record the start time of use when it is detected that the grooved wheel or bob has been installed and the wire cutting machine has started processing. When the removal of the grooved wheel or spool is detected, or when the wire cutter stops processing, the end time of use is recorded; The actual usage time is calculated based on the start and end times. Based on preset standard lifespan parameters and actual usage time, the remaining lifespan is dynamically calculated; when the remaining lifespan is lower than the preset warning threshold, a warning message is triggered.

2. The method according to claim 1, characterized in that, The installation status of the grooved wheel or spool is detected by installation detection sensors installed at the grooved wheel mounting position and the spool loading position; the start-up status of the wire cutting machine is detected by a processing start sensor installed in the wire cutting machine's electrical control unit.

3. The method according to claim 2, characterized in that, The sensor includes at least one of a photoelectric sensor, a pressure sensor, or a proximity switch.

4. The method according to any one of claims 1-3, characterized in that, Both the grooved wheel and the spool are equipped with a unique identifier, which is a QR code or an RFID tag.

5. The method according to claim 4, characterized in that, The method further includes: Establish a relationship between the Geneva or spool identifier and the standard life parameters in the database; Update the cumulative usage time and remaining lifespan corresponding to this identifier after each use.

6. The method according to any one of claims 1-3 and 5, characterized in that, The start and end times are recorded using a timer, and the trigger condition for the timer is: The recording conditions for the start time are: receiving a signal that the groove wheel or spool has been installed and a signal that the wire cutting machine has started processing; The conditions for recording the end time are: receiving a signal that the grooved wheel or spool is not installed, or receiving a signal that the wire cutting machine has completed processing and there are no subsequent processing tasks.

7. The method according to claim 1, characterized in that, The formula for dynamically calculating the remaining lifetime is: Remaining lifespan = Standard lifespan - Cumulative usage time; 8. The method according to claim 1, characterized in that, The warning notification includes at least one of the following: audible and visual alarm, display screen notification, or sending warning information to the MES system.

9. The method according to any one of claims 1-3, 5, and 7-8, characterized in that, Also includes: The start time, end time, cumulative duration, and remaining lifespan data for each use are uploaded to the EAP system in real time. Data is synchronized to the factory's MES system through the EAP system for production planning optimization and procurement decision support. Analyze the wear trends of wheel hubs or spools based on historical lifespan data to identify batches with abnormal wear. Adjust procurement strategies or update standard life parameters based on the analysis results.

10. A system for automated monitoring and intelligent early warning of the lifespan of a grooved wheel spool for implementing the method as described in any one of claims 1-9, characterized in that, include: The sensor group includes an installation detection sensor for detecting whether the grooved wheel or spool is installed in place, and a processing start sensor for detecting whether the wire cutting machine has started processing. The data acquisition and processing module is connected to the sensor group and is used to receive sensor signals and trigger timing and record the start and end times of use according to preset logic. The life management database is used to store the unique identifier of each groove wheel or spool, the corresponding standard life parameters, the duration of each use, and the calculated remaining life data. The early warning interaction module is connected to the lifespan management database and is used to issue an early warning when the remaining lifespan is lower than a threshold, and to provide a human-computer interaction interface.

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