Main shaft dynamic balance test method and system based on intelligent sensor

Abstract

The invention discloses a main shaft dynamic balance test method and system based on an intelligent sensor. The method comprises the steps that radial vibration data of a to-be-tested main shaft are collected in real time and preprocessed; predicting to obtain a predicted comprehensive score; establishing a preset sample library, and determining a voltage fluctuation interval corresponding to each main shaft sample in the library; and when the predicted comprehensive score is not in a preset comprehensive score interval, determining a voltage basic adjustment unit according to the voltage fluctuation interval of the main shaft sample or the analyzed and predicted comprehensive score to adjust the voltage of the electric field, and if the adjustment of the analyzed and predicted comprehensive score is passed, collecting the real vibration data of the adjusted to-be-measured main shaft. Determining a correction coefficient and correcting the voltage basic regulation unit; the temperature of the to-be-measured spindle is collected in real time, and when the temperature reaches a preset value, the to-be-measured spindle is adjusted. The high-precision dynamic balance control of the main shaft is realized by collecting and predicting the vibration data of the main shaft in real time and dynamically adjusting the voltage of the electric field.

Description

Technical Field

[0001] This application relates to the field of spindle dynamic balancing technology, and more specifically, to a spindle dynamic balancing test method and system based on intelligent sensors. Background Technology

[0002] In the field of machine tool processing, the dynamic balance of the machine tool spindle plays a crucial role in machining accuracy and equipment stability. During actual machining, any dynamic imbalance in the spindle will cause severe vibration and noise, leading to decreased machining accuracy, defects such as ripples and vibration marks on the workpiece surface, and accelerated wear on components such as spindle bearings, thus reducing the machine tool's service life and reliability.

[0003] Traditional machine tool spindle dynamic balancing technology mostly employs offline balancing methods, meaning that measurements and adjustments are performed using specialized balancing equipment after the spindle has stopped running. This method is not only cumbersome and time-consuming, but also unable to address spindle dynamic imbalances caused by factors such as tool wear and uneven workpiece material during machining in real time. With the ever-increasing demands for machining accuracy and production efficiency in modern manufacturing, traditional offline dynamic balancing technology is no longer sufficient, necessitating an online dynamic balancing technology capable of real-time monitoring and adjustment of the spindle's dynamic balance.

[0004] The electrorheological effect refers to the phenomenon that the rheological properties (such as viscosity and shear stress) of certain materials change rapidly, reversibly, and continuously under the influence of an electric field. Materials based on the electrorheological effect have shown great application potential in the field of intelligent control, but they are not yet widely used in online dynamic balancing technology for machine tool spindles. Summary of the Invention

[0005] This invention aims to introduce the electrorheological effect into the field of online dynamic balancing of machine tool spindles, and proposes a brand-new online dynamic balancing technology solution for machine tool spindles based on the electrorheological effect. By leveraging the properties of electrorheological materials, this invention solves the problems existing in traditional dynamic balancing technology, realizes real-time dynamic balance adjustment of the spindle during operation, and improves the machining accuracy and stability of the machine tool.

[0006] The first aspect of this invention provides a spindle dynamic balancing test method based on intelligent sensors, comprising: Real-time acquisition and preprocessing of radial vibration data of the spindle under test yields real-time spindle frequency, rotational frequency, and spindle amplitude. Based on the real-time spindle frequency, rotation frequency and spindle amplitude, the comprehensive vibration score is calculated, the comprehensive vibration score curve is plotted and the predicted comprehensive score is predicted after a preset time period. Establish a preset sample library, acquire and analyze the historical operating data of each spindle sample in the preset sample library, and determine the voltage fluctuation range corresponding to each spindle sample. When the predicted comprehensive score is not within the preset comprehensive score range, spindle dynamic balance correction is performed. If there is a spindle sample in the preset sample library that meets the preset sample requirements, the electric field voltage is adjusted based on the corresponding voltage fluctuation range. If there is no spindle sample in the preset sample library that meets the preset sample requirements, the predicted comprehensive score is analyzed to determine the voltage increase / decrease state and the basic voltage adjustment unit; the electric field voltage is adjusted according to the voltage increase / decrease state and the basic voltage adjustment unit, and the real vibration data of the spindle under test is collected in real time, and the correction coefficient is determined based on the real vibration data. The voltage base adjustment unit is corrected according to the correction factor, and the electric field voltage is adjusted based on the corrected voltage base adjustment unit; The temperature of the spindle under test is collected in real time, and the spindle is adjusted when the temperature reaches the preset high temperature value.

[0007] In this scheme, the real-time acquisition and preprocessing of the radial vibration data of the spindle under test to obtain the real-time spindle frequency, rotational frequency, and spindle amplitude includes: The vibration data of the spindle under test is collected in real time by a vibration sensor, and the vibration data of the spindle under test is converted into frequency domain data by frequency domain conversion. Extract frequency features from the frequency domain data, including real-time spindle frequency, rotation frequency, and spindle amplitude.

[0008] In this solution, the step of calculating the comprehensive vibration score based on the real-time spindle frequency, rotation frequency, and spindle amplitude, plotting the comprehensive vibration score curve, and predicting the predicted comprehensive score after a preset time period includes: Calculate the difference between the spindle frequency and the rotational frequency; The comprehensive vibration score is calculated based on the difference between the spindle frequency and the rotation frequency and the corresponding spindle amplitude, according to a preset weight. Based on the comprehensive vibration score, a comprehensive vibration score curve is plotted with the comprehensive vibration score on the vertical axis and time on the horizontal axis. The predicted comprehensive score is predicted after a preset time period based on the trend of the comprehensive vibration score curve.

[0009] In this solution, the step of establishing a preset sample library, acquiring and analyzing the historical operating data of each spindle sample in the preset sample library, and determining the voltage fluctuation range corresponding to each spindle sample includes: Establish a preset sample library and acquire historical operating data for each spindle sample in the preset sample library, including spindle sample information, operating environment, real-time vibration data and corresponding real-time electric field voltage; The corresponding real-time sample comprehensive score is calculated based on the real-time vibration data of each spindle sample. The real-time sample comprehensive score corresponding to each spindle sample is analyzed, and the electric field voltage corresponding to the spindle sample whose real-time sample comprehensive score is within the preset comprehensive score range is added to the electric field voltage sequence. The maximum and minimum values ​​in the electric field voltage sequence corresponding to each master shaft sample are selected to form the voltage fluctuation range for each master shaft sample.

[0010] In this scheme, when the predicted comprehensive score is not within the preset comprehensive score range, spindle dynamic balancing correction is performed. If a spindle sample that meets the preset sample requirements exists in the preset sample library, the electric field voltage is adjusted based on the corresponding voltage fluctuation range, including: Based on the spindle sample information and operating environment in the preset sample library, if there is a spindle sample that meets the preset sample requirements, the voltage fluctuation range corresponding to the spindle sample is selected as the standard voltage range of the spindle to be tested. According to the standard voltage range, the electric field voltage is gradually adjusted to the standard voltage range according to the preset adjustment unit.

[0011] In this scheme, the analysis of the predicted comprehensive score to determine the voltage increase / decrease state and the basic voltage adjustment unit includes: If the predicted comprehensive vibration score is greater than the maximum value of the preset comprehensive score range, then the voltage increase / decrease state is to increase the electric field voltage; If the predicted comprehensive vibration score is less than the minimum value of the preset comprehensive score interval, the comprehensive vibration score curve is analyzed, and the average value of the comprehensive vibration score change rate corresponding to the predicted comprehensive score time and the first three monitoring points is calculated. If the average value of the comprehensive vibration score change rate is less than the preset change rate value, the voltage increase / decrease state is to decrease the voltage. The predicted comprehensive score is analyzed, and the difference e between the predicted comprehensive vibration score and the maximum value of the preset comprehensive vibration score interval and the difference f between the predicted comprehensive vibration score and the minimum value of the preset comprehensive vibration score interval are calculated respectively. Based on the difference e between the predicted comprehensive vibration score and the maximum value of the preset comprehensive vibration score interval, and the difference f between the predicted comprehensive vibration score and the minimum value of the preset comprehensive vibration score interval, the voltage base adjustment unit is determined according to the preset adjustment unit determination method, including the voltage base adjustment unit when increasing the electric field voltage and the voltage base adjustment unit when decreasing the electric field voltage.

[0012] In this scheme, the adjustment of the electric field voltage based on the voltage increase / decrease state and the voltage base adjustment unit, and the real vibration data of the spindle under test being collected in real time, and the determination of the correction coefficient based on the real vibration data, include: The electric field voltage is adjusted according to the voltage increase / decrease state and the voltage base adjustment unit. During the adjustment process, real vibration data is collected in real time and the real vibration score is calculated. The real change curve of the real vibration score over time is plotted. Based on the voltage basic adjustment unit, historical data is obtained and an ideal comprehensive score change curve is plotted according to a preset curve plotting method; The absolute value of the difference between the area enclosed by the two curves when the ideal comprehensive score change curve is below the actual change curve and the area enclosed by the two curves when the ideal comprehensive score change curve is above the actual change curve during the voltage regulation period is used as the first difference value M. When the first difference M is greater than the threshold, the voltage regulation unit is corrected. Calculate the second difference A between the ordinate of the actual change curve at the time node corresponding to the first difference M being greater than the threshold and the ordinate of the curve corresponding to the predicted comprehensive vibration score at the time node; Based on the actual change curve, calculate the rate of change of the comprehensive vibration score V1 at the corresponding time node when the first difference M is greater than the threshold. Based on the comprehensive vibration score change rate V1 and the second difference A, the adjusted comprehensive vibration score change rate V2 is calculated as follows: V2 = V1 + A / t; Where t is the difference between the preset correction time and the time node corresponding to the first difference M being greater than the threshold; Based on the adjusted rate of change of the comprehensive vibration score V2, the correction coefficient is determined.

[0013] In this scheme, the step of correcting the voltage base adjustment unit according to the correction coefficient and adjusting the electric field voltage based on the corrected voltage base adjustment unit includes: Calculate the product of the correction factor and the voltage base adjustment unit to obtain the corrected voltage base adjustment unit; The electric field voltage between the time node corresponding to the first difference M being greater than the threshold and the preset correction time is adjusted according to the corrected voltage base adjustment unit, and the electric field voltage corresponding to the preset correction time is continuously output as the final voltage.

[0014] In this solution, the real-time acquisition of the temperature of the spindle under test, and the adjustment of the spindle under test when the temperature reaches a preset high temperature value, includes: A temperature sensor is used to collect the temperature in real time. When the temperature reaches the preset high temperature value, the temperature protection mechanism is activated, the spindle speed is reduced to the first preset speed value, and the heat dissipation system is activated. When the temperature drops to the preset low temperature value, the cooling system is turned off and the spindle speed is increased to the second preset speed value.

[0015] The second aspect provides a spindle dynamic balancing test system based on intelligent sensors, including: The data acquisition module is used to acquire the radial vibration data of the spindle under test in real time and perform preprocessing to obtain the real-time spindle frequency, rotational frequency and spindle amplitude. The first data analysis module is used to calculate the comprehensive vibration score based on the real-time spindle frequency, rotation frequency and spindle amplitude, draw the comprehensive vibration score curve and predict the predicted comprehensive score after a preset time period. The sample testing module is used to establish a preset sample library, acquire and analyze the historical operating data of each spindle sample in the preset sample library, and determine the voltage fluctuation range corresponding to each spindle sample. The first voltage adjustment module performs spindle dynamic balance correction when the predicted comprehensive score is not within the preset comprehensive score range. If there is a spindle sample in the preset sample library that meets the preset sample requirements, the electric field voltage is adjusted based on the corresponding voltage fluctuation range. The second data analysis module analyzes the predicted comprehensive score if there is no spindle sample in the preset sample library that meets the preset sample requirements, determines the voltage increase / decrease state and the basic voltage adjustment unit, adjusts the electric field voltage according to the voltage increase / decrease state and the basic voltage adjustment unit, and collects the real vibration data of the spindle under test in real time, and determines the correction coefficient based on the real vibration data. The second voltage regulation module is used to correct the voltage base regulation unit according to the correction coefficient and to regulate the electric field voltage based on the corrected voltage base regulation unit. The temperature monitoring module is used to collect the temperature of the spindle under test in real time. When the temperature reaches the preset high temperature value, the spindle under test is adjusted.

[0016] This invention discloses a spindle dynamic balancing test method and system based on intelligent sensors. The method includes: real-time acquisition and preprocessing of radial vibration data of the spindle under test; prediction of a comprehensive score; establishment of a preset sample library, determining the voltage fluctuation range corresponding to each spindle sample in the library; when the predicted comprehensive score is not within the preset comprehensive score range, adjusting the electric field voltage according to the voltage fluctuation range of the spindle sample or by analyzing the predicted comprehensive score; if adjustment is made by analyzing the predicted comprehensive score, acquiring the actual vibration data of the spindle under test after adjustment, determining the correction coefficient, and correcting the voltage base adjustment unit; real-time acquisition of the temperature of the spindle under test, and adjusting the spindle under test when the temperature reaches a preset value. This invention achieves high-precision dynamic balancing control of the spindle by real-time acquisition and prediction of spindle vibration data and dynamic adjustment of the electric field voltage. Attached Figure Description

[0017] Figure 1A flowchart of a spindle dynamic balancing test method based on a smart sensor provided by the present invention is shown; Figure 2 A simplified diagram illustrating the working principle of online dynamic balancing of machine tool spindles based on electrorheological effect is shown. Figure 3 A block diagram of a spindle dynamic balancing test system based on a smart sensor provided by the present invention is shown. Detailed Implementation

[0018] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0019] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0020] Figure 1 A flowchart of a spindle dynamic balancing test method based on a smart sensor provided by the present invention is shown; like Figure 1 As shown, this invention discloses a spindle dynamic balancing test method based on intelligent sensors, comprising: S101, real-time acquisition of radial vibration data of the spindle under test and preprocessing to obtain real-time spindle frequency, rotational frequency and spindle amplitude; S102: Calculate the comprehensive vibration score based on the real-time spindle frequency, rotation frequency and spindle amplitude, plot the comprehensive vibration score curve and predict the predicted comprehensive score after a preset time period. S103, Establish a preset sample library, obtain and analyze the historical operating data of each spindle sample in the preset sample library, and determine the voltage fluctuation range corresponding to each spindle sample. S104, when the predicted comprehensive score is not within the preset comprehensive score range, spindle dynamic balance correction is performed. If there is a spindle sample in the preset sample library that meets the preset sample requirements, the electric field voltage is adjusted based on the corresponding voltage fluctuation range. S105, If there is no spindle sample in the preset sample library that meets the preset sample requirements, the predicted comprehensive score is analyzed to determine the voltage increase / decrease state and the voltage basic adjustment unit; the electric field voltage is adjusted according to the voltage increase / decrease state and the voltage basic adjustment unit, and the real vibration data of the spindle under test is collected in real time, and the correction coefficient is determined based on the real vibration data. S106, Correct the voltage base adjustment unit according to the correction factor and adjust the electric field voltage based on the corrected voltage base adjustment unit; S107 collects the temperature of the spindle under test in real time, and adjusts the spindle under test when the temperature reaches the preset high temperature value.

[0021] According to an embodiment of the present invention, high-precision vibration sensors installed at key parts of the machine tool spindle end collect radial vibration data of the spindle in real time. The collected vibration data is preprocessed to obtain the radial spindle frequency, rotational frequency, and spindle amplitude. The difference between the spindle frequency and rotational frequency is calculated, and a comprehensive vibration score is calculated based on the difference and the corresponding spindle amplitude according to a preset weight. A comprehensive vibration score curve is plotted based on the comprehensive vibration score. The predicted comprehensive score for a preset time period is predicted based on the trend of the comprehensive vibration score curve. The dynamic balance state of the spindle for the future time period is determined based on the predicted comprehensive score. A spindle sample library is established, and historical operating data of each spindle sample in the sample library is obtained. The comprehensive score of each spindle sample is calculated based on the historical operating data. The comprehensive score of each spindle sample is analyzed, and the electric field voltage corresponding to the comprehensive score within a preset comprehensive score range is added to an electric field voltage sequence. The maximum and minimum voltages in the electric field voltage sequence corresponding to each spindle sample are selected to form a... For each spindle sample, a voltage fluctuation range is defined. When the predicted comprehensive score does not meet the requirements and the electric field voltage needs adjustment, a spindle sample from the spindle sample library that meets the preset sample requirements is selected. The voltage fluctuation range of this spindle sample is obtained and used as the standard voltage range for the spindle under test. The electric field voltage is then gradually adjusted. When no spindle sample meets the preset sample requirements, the predicted comprehensive score is analyzed to determine the voltage increase / decrease state. The predicted comprehensive score is analyzed in conjunction with the preset comprehensive vibration score range to determine the basic voltage adjustment unit. The electric field voltage is adjusted according to the voltage increase / decrease state and the basic voltage adjustment unit. The actual vibration data of the spindle under test is recorded in real time. The actual vibration data is analyzed to obtain the correction coefficient for the basic voltage adjustment unit, and the basic voltage adjustment unit is corrected. The corrected basic voltage adjustment unit is used to further adjust the electric field voltage to achieve spindle dynamic balance. Simultaneously, the temperature of the spindle under test is collected in real time. When the temperature reaches the preset high temperature, heat dissipation is activated to reduce the rotational speed, further ensuring continuous spindle dynamic balance.

[0022] Figure 2A simplified diagram illustrating the online dynamic balancing principle of a machine tool spindle based on the electrorheological effect is shown. The electric field adjustment system influences the mechanical properties of the electrorheological material by adjusting the electric field voltage, thereby affecting the dynamic balance state of the spindle. Vibration sensors are used to collect the vibration signals of the spindle in real time and transmit the signals collected by the vibration sensors to the control system through a signal transmission line. The controller precisely adjusts the voltage and frequency of the power supply output according to the instructions of the control system. The driver amplifies the power of the signal output by the controller to meet the requirements of the electrodes for electric field strength. The cavity provides a closed and stable working space for the electrorheological material, ensuring that the electrorheological material can form a uniform and reliable structure under the action of the electric field. Under the control of the applied electric field, the electrorheological material can change its own damping coefficient and equivalent stiffness in real time, thereby actively suppressing the vibration of the spindle and adjusting its dynamic balance. The spindle core, as the core rotating base of the spindle, undertakes the clamping and positioning of the workpiece or tool and the power transmission, ensuring the rotational accuracy and structural rigidity of the spindle under high-speed rotation.

[0023] According to an embodiment of the present invention, real-time acquisition and preprocessing of the radial vibration data of the spindle under test to obtain the real-time spindle frequency, rotational frequency, and spindle amplitude includes: The vibration data of the spindle under test is collected in real time by a vibration sensor, and the vibration data of the spindle under test is converted into frequency domain data by frequency domain conversion. Extract frequency features from the frequency domain data, including real-time spindle frequency, rotation frequency, and spindle amplitude.

[0024] It should be noted that Fourier transform is used to convert the radial vibration data of the spindle under test into the frequency domain. By discretizing the continuous time domain signal to construct a discrete time series, and then performing a fast Fourier transform operation on the discrete time series, frequency domain data is obtained, which provides a reliable basis for real-time judgment of the spindle dynamic balance state and accurate calculation of the imbalance.

[0025] According to an embodiment of the present invention, a comprehensive vibration score is calculated based on real-time spindle frequency, rotational frequency, and spindle amplitude; a comprehensive vibration score curve is plotted; and a predicted comprehensive score is predicted after a preset time period, including: Calculate the difference between the spindle frequency and the rotational frequency; The comprehensive vibration score is calculated based on the difference between the spindle frequency and the rotation frequency and the corresponding spindle amplitude, according to preset weights. A comprehensive vibration score curve is plotted based on the comprehensive vibration score, with the comprehensive vibration score on the vertical axis and time on the horizontal axis. The predicted comprehensive score is predicted based on the trend of the comprehensive vibration score curve after a preset time period.

[0026] It should be noted that the difference between the spindle frequency and the rotation frequency and the corresponding spindle amplitude are weighted according to the preset weights. For example, the difference between the spindle frequency and the rotation frequency is 0.3, and the corresponding spindle amplitude is 0.7. Dimensionless calculation is used in the calculation process.

[0027] The difference between the spindle frequency and the rotational frequency can quantify the impact of speed fluctuations on the spindle's operational stability. Combined with the spindle amplitude, which reflects vibration intensity, a weighted calculation is performed to obtain a comprehensive vibration score, which can uniformly characterize the spindle's dynamic balance state.

[0028] By plotting the comprehensive vibration score curve and predicting the comprehensive score after a preset time period based on the curve trend, the future vibration state and dynamic balance deterioration trend of the spindle can be predicted in advance, providing data support for real-time dynamic balance adjustment during spindle operation.

[0029] The preset weights and preset time periods can be set by professionals in the field according to the actual situation.

[0030] According to an embodiment of the present invention, a preset sample library is established, historical operating data of each spindle sample in the preset sample library is acquired and analyzed, and the voltage fluctuation range corresponding to each spindle sample is determined, including: Establish a preset sample library and acquire historical operating data for each spindle sample in the preset sample library, including spindle sample information, operating environment, real-time vibration data and corresponding real-time electric field voltage; The real-time sample comprehensive score is calculated based on the real-time vibration data of each spindle sample. The real-time sample comprehensive score corresponding to each spindle sample is analyzed separately, and the electric field voltage corresponding to the spindle sample whose real-time sample comprehensive score is within the preset comprehensive score range (e.g., 70-90) is added to the electric field voltage sequence. The maximum and minimum values ​​in the electric field voltage sequence corresponding to each master shaft sample are selected to form the voltage fluctuation range for each master shaft sample.

[0031] It should be noted that the spindle sample information includes the spindle sample lifespan and model, which, together with the operating environment, are used to ensure the accurate matching between the spindle under test and the spindle sample. By acquiring and analyzing the historical operating data of the spindle samples in the preset sample library, the voltage fluctuation range corresponding to the sample comprehensive score of the spindle sample within the preset comprehensive score range, i.e., when the spindle sample is in normal dynamic balance, is obtained. This provides a stable and reliable voltage reference for electric field adjustment during the subsequent operation of the spindle under test.

[0032] When calculating the real-time sample comprehensive score based on the real-time vibration data of each spindle sample, the real-time vibration data must first be converted to the frequency domain to obtain the corresponding spindle amplitude, spindle frequency, and rotational frequency, and the difference between the spindle frequency and the rotational frequency must be calculated. The method for calculating the real-time sample comprehensive score based on the spindle amplitude and the difference between the spindle frequency and the rotational frequency is the same as the method for calculating the comprehensive vibration score, but the preset weights corresponding to the calculation of the real-time sample comprehensive score need to be set according to the specific situation of the spindle sample.

[0033] The preset comprehensive score range can be specifically set by professionals in this field according to the actual situation.

[0034] According to an embodiment of the present invention, when the predicted comprehensive score is not within a preset comprehensive score range, spindle dynamic balancing correction is performed. If a spindle sample that meets the preset sample requirements exists in the preset sample library, the electric field voltage is adjusted based on the corresponding voltage fluctuation range, including: Based on the spindle sample information and operating environment in the preset sample library, if there is a spindle sample that meets the preset sample requirements, the voltage fluctuation range corresponding to the spindle sample is selected as the standard voltage range of the spindle to be tested. Based on the standard voltage range, the electric field voltage is gradually adjusted to the standard voltage range according to the preset adjustment unit.

[0035] It should be noted that the preset sample requirements are, for example, that the lifespan of the spindle sample in the spindle sample information differs from that of the spindle to be tested by no more than one month, and that the model and operating environment are the same; by accurately matching the spindle sample and the sample to be tested, the standard voltage range of the sample to be tested can be directly obtained, reducing repeated debugging, improving the efficiency of electric field adjustment and the accuracy of dynamic balance control, and enhancing the system's adaptive and rapid adjustment capabilities.

[0036] The purpose of gradually adjusting the electric field voltage according to a preset adjustment unit (e.g., 1mV / min) is to avoid sudden voltage changes that could cause instantaneous increased vibration of the spindle, leading to equipment damage or operational interruption. Gradual voltage adjustment ensures that the spindle remains in a stable operating state during the adjustment process, while also facilitating real-time monitoring of vibration data and improving the reliability and stability of the electric field adjustment.

[0037] The preset sample requirements and preset adjustment units can be set by professionals in the field according to the actual situation.

[0038] According to an embodiment of the present invention, the predicted comprehensive score is analyzed to determine the voltage increase / decrease state and the basic voltage adjustment unit, including: If the predicted comprehensive vibration score is greater than the maximum value of the preset comprehensive score range, then the voltage increase / decrease state is to increase the electric field voltage; If the predicted comprehensive vibration score is less than the minimum value of the preset comprehensive score range, the comprehensive vibration score curve is analyzed, and the average value of the comprehensive vibration score change rate corresponding to the predicted comprehensive score time and the first three monitoring points is calculated. If the average value of the comprehensive vibration score change rate is less than the preset change rate value, the voltage increase / decrease state is to decrease the voltage. The predicted comprehensive score is analyzed, and the difference e between the predicted comprehensive vibration score and the maximum value of the preset comprehensive vibration score interval and the difference f between the predicted comprehensive vibration score and the minimum value of the preset comprehensive vibration score interval are calculated respectively. Based on the difference e between the predicted comprehensive vibration score and the maximum value of the preset comprehensive vibration score interval, and the difference f between the predicted comprehensive vibration score and the minimum value of the preset comprehensive vibration score interval, the voltage base adjustment unit is determined according to the preset adjustment unit determination method, including the voltage base adjustment unit when increasing the electric field voltage and the voltage base adjustment unit when decreasing the electric field voltage.

[0039] It should be noted that if the predicted comprehensive vibration score is greater than the maximum value of the preset comprehensive score range, it indicates that the main shaft has unbalanced vibration, which is essentially forced vibration caused by excessive centrifugal force. Therefore, it is necessary to increase the electric field voltage, thereby increasing the damping coefficient and equivalent stiffness of the electrorheological material, effectively enhancing the support rigidity of the main shaft, reducing the amplitude and frequency of the unbalanced vibration of the main shaft, and restoring the main shaft to dynamic balance. If the predicted comprehensive vibration score is less than the minimum value of the preset comprehensive score range, and the comprehensive vibration score tends to be stable at the time of the predicted comprehensive vibration score and at the first three monitoring points, the electric field voltage can be appropriately reduced to reduce energy consumption and improve the service life of the electrorheological material while meeting the operating requirements.

[0040] The method for determining the preset adjustment unit is as follows: For example, multiple corresponding intervals are set for the difference e between the predicted comprehensive vibration score and the maximum value of the preset comprehensive vibration score interval, and the difference f between the predicted comprehensive vibration score and the minimum value of the preset comprehensive vibration score interval. The voltage base adjustment unit for each interval is set based on historical data. For instance, for the difference e, when the difference e is greater than or equal to 10, the voltage base adjustment unit for increasing the electric field voltage is 10V; when the difference e is greater than or equal to 5 but less than 10, the voltage base adjustment unit for increasing the electric field voltage is 8V; when the difference e is greater than or equal to 0 but less than 5, the voltage base adjustment unit for increasing the electric field voltage is 5V. For the difference f, when the difference f is greater than or equal to 10, the voltage base adjustment unit for decreasing the electric field voltage is 15V; when the difference f is greater than or equal to 5 but less than 10, the voltage base adjustment unit for decreasing the electric field voltage is 10V; when the difference f is greater than or equal to 0 but less than 5, the voltage base adjustment unit for decreasing the electric field voltage is 5V.

[0041] The preset rate of change value and the preset adjustment unit determination method can be set by professionals in this field according to the actual situation.

[0042] According to an embodiment of the present invention, the electric field voltage is adjusted according to the voltage increase / decrease state and the voltage base adjustment unit, and the real vibration data of the spindle under test is collected in real time. A correction coefficient is determined based on the real vibration data, including: The electric field voltage is adjusted according to the voltage increase / decrease state and the voltage base adjustment unit. During the adjustment process, real vibration data is collected in real time and the real vibration score is calculated. The real change curve of the real vibration score over time is plotted. Based on the voltage-based adjustment unit, historical data is acquired and an ideal comprehensive score change curve is plotted according to a preset curve plotting method. The absolute value of the difference between the area enclosed by the two curves when the ideal comprehensive score change curve is below the actual change curve and the area enclosed by the two curves when the ideal comprehensive score change curve is above the actual change curve during the voltage regulation period is used as the first difference value M. When the first difference M is greater than the threshold, the voltage regulation unit is corrected. Calculate the second difference A between the ordinate of the actual change curve at the time node corresponding to the first difference M being greater than the threshold and the ordinate of the curve corresponding to the predicted comprehensive vibration score at the same time node; Based on the actual change curve, calculate the rate of change of the comprehensive vibration score V1 at the corresponding time node when the first difference M is greater than the threshold. Based on the comprehensive vibration score change rate V1 and the second difference A, the adjusted comprehensive vibration score change rate V2 is calculated as follows: V2 = V1 + A / t; Where t is the difference between the preset correction time and the time node corresponding to the first difference M being greater than the threshold; The correction coefficient is determined based on the adjusted rate of change of the overall vibration score, V2.

[0043] It should be noted that the historical data refers to the vibration time-domain data and corresponding electric field voltage of the spindle under test during its operation over a past historical period. The preset curve plotting method is, for example, to analyze and calculate the historical data to obtain the changes in the comprehensive vibration score and the corresponding changes in electric field voltage of the spindle under test over a past historical period, and to plot the ideal comprehensive score change curve by combining the voltage base adjustment unit.

[0044] The first difference M represents the difference between the actual vibration recovery and the ideal vibration recovery during the voltage adjustment period. Therefore, when the first difference M is greater than the threshold, it indicates that the electric field voltage adjustment is insufficient and needs to be corrected to meet the real-time adjustment of the spindle dynamic balance and avoid affecting normal production operation. The specific method for determining the correction coefficient based on the adjusted comprehensive vibration score change rate V2 is as follows: For example, the correction coefficient can be determined by looking up a table. A one-to-one correspondence between different V2 intervals and correction coefficients is established in advance according to the actual situation and stored as a lookup table. The corresponding interval is matched according to the current adjusted comprehensive vibration score change rate V2, and the correction coefficient under the current working condition is obtained directly by looking up the table. For example, when V2>1, the correction coefficient is 1.5.

[0045] The preset curve plotting method, threshold, and preset correction time can be specifically set by professionals in the field according to the actual situation.

[0046] According to an embodiment of the present invention, correcting the voltage base adjustment unit according to a correction factor and adjusting the electric field voltage based on the corrected voltage base adjustment unit includes: Calculate the product of the correction factor and the voltage base adjustment unit to obtain the corrected voltage base adjustment unit; The electric field voltage between the time node corresponding to the first difference M being greater than the threshold and the preset correction time is adjusted according to the corrected voltage base adjustment unit, and the electric field voltage corresponding to the preset correction time is continuously output as the final voltage.

[0047] It should be noted that adjusting the voltage base adjustment unit through the calculated correction coefficient aims to achieve adaptive optimization of the electric field voltage adjustment step size. This allows for the adjustment of the electric field voltage before spindle imbalance is predicted, avoiding overshoot or lag issues caused by a fixed adjustment step size and improving the machine tool's production efficiency.

[0048] According to an embodiment of the present invention, the temperature of the spindle under test is acquired in real time, and when the temperature reaches a preset high temperature value, the spindle under test is adjusted, including: A temperature sensor is used to collect the temperature in real time. When the temperature reaches the preset high temperature value, the temperature protection mechanism is activated, the spindle speed is reduced to the first preset speed value, and the heat dissipation system is activated. When the temperature drops to the preset low temperature value, the cooling system is turned off and the spindle speed is increased to the second preset speed value.

[0049] It should be noted that the first preset speed value is the minimum speed value under normal production operation conditions during the spindle operation. The purpose of reducing the spindle speed to the first preset speed value is to reduce the heat generated by the spindle rotation, so that the spindle temperature drops faster, extend the spindle life, and reduce the impact on the spindle dynamic balance. The second preset speed value is the optimal value for production operation. When the spindle temperature drops to the preset low temperature value, the speed is increased to the optimal value for production operation to improve production efficiency.

[0050] The preset high temperature value, the first preset speed value, the preset low temperature value, and the second preset speed value can be specifically set by professionals in the field according to the actual situation.

[0051] Figure 3 A block diagram of a spindle dynamic balancing test system based on a smart sensor provided by the present invention is shown.

[0052] like Figure 3 As shown, a second aspect of the present invention provides a spindle dynamic balancing test system based on intelligent sensors, comprising: The data acquisition module is used to acquire the radial vibration data of the spindle under test in real time and perform preprocessing to obtain the real-time spindle frequency, rotational frequency and spindle amplitude. The first data analysis module is used to calculate the comprehensive vibration score based on the real-time spindle frequency, rotation frequency and spindle amplitude, draw the comprehensive vibration score curve and predict the predicted comprehensive score after a preset time period. The sample testing module is used to establish a preset sample library, acquire and analyze the historical operating data of each spindle sample in the preset sample library, and determine the voltage fluctuation range corresponding to each spindle sample. The first voltage adjustment module performs spindle dynamic balance correction when the predicted comprehensive score is not within the preset comprehensive score range. If there is a spindle sample in the preset sample library that meets the preset sample requirements, the electric field voltage is adjusted based on the corresponding voltage fluctuation range. The second data analysis module analyzes the predicted comprehensive score if there is no spindle sample in the preset sample library that meets the preset sample requirements, determines the voltage increase / decrease state and the basic voltage adjustment unit, adjusts the electric field voltage according to the voltage increase / decrease state and the basic voltage adjustment unit, and collects the real vibration data of the spindle under test in real time, and determines the correction coefficient based on the real vibration data. The second voltage regulation module is used to correct the voltage base regulation unit according to the correction coefficient and to regulate the electric field voltage based on the corrected voltage base regulation unit. The temperature monitoring module is used to collect the temperature of the spindle under test in real time. When the temperature reaches the preset high temperature value, the spindle under test is adjusted.

[0053] All information (including but not limited to user equipment information, user personal information, etc.), data (including but not limited to data used for analysis, stored data, displayed data, etc.), and signals (including but not limited to signals transmitted between user terminals and other devices) involved in this application have been authorized by the user or fully authorized by all parties, and the collection, use, and processing of related data must comply with the relevant laws, regulations, and standards of the relevant countries and regions. For example, the "electric field voltage" mentioned in this disclosure was obtained under full authorization.

[0054] This invention discloses a spindle dynamic balancing test method and system based on intelligent sensors. The method includes: real-time acquisition and preprocessing of radial vibration data of the spindle under test; prediction of a comprehensive score; establishment of a preset sample library, determining the voltage fluctuation range corresponding to each spindle sample in the library; when the predicted comprehensive score is not within the preset comprehensive score range, adjusting the electric field voltage according to the voltage fluctuation range of the spindle sample or by analyzing the predicted comprehensive score; if adjustment is made by analyzing the predicted comprehensive score, acquiring the actual vibration data of the spindle under test after adjustment, determining the correction coefficient, and correcting the voltage base adjustment unit; real-time acquisition of the temperature of the spindle under test, and adjusting the spindle under test when the temperature reaches a preset value. This invention achieves high-precision dynamic balancing control of the spindle by real-time acquisition and prediction of spindle vibration data and dynamic adjustment of the electric field voltage.

[0055] In the several embodiments provided in this application, it should be understood that the disclosed devices and methods can be implemented in other ways. The device embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and in actual implementation, there may be other division methods, such as: multiple units or components can be combined, or integrated into another system, or some features can be ignored or not executed. In addition, the coupling, direct coupling, or communication connection between the various components shown or discussed can be through some interfaces, and the indirect coupling or communication connection between devices or units can be electrical, mechanical, or other forms.

[0056] The units described above as separate components may or may not be physically separate. The components shown as units may or may not be physical units. They may be located in one place or distributed across multiple network units. Some or all of the units may be selected to achieve the purpose of this embodiment according to actual needs.

[0057] In addition, in the various embodiments of the present invention, each functional unit can be integrated into one processing unit, or each unit can be a separate unit, or two or more units can be integrated into one unit; the integrated unit can be implemented in hardware or in the form of hardware plus software functional units.

[0058] Those skilled in the art will understand that all or part of the steps of the above method embodiments can be implemented by hardware related to program instructions. The aforementioned program can be stored in a computer-readable storage medium. When the program is executed, it performs the steps of the above method embodiments. The aforementioned storage medium includes various media capable of storing program code, such as mobile storage devices, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0059] Alternatively, if the integrated units of this invention are implemented as software functional modules and sold or used as independent products, they can also be stored in a computer-readable storage medium. Based on this understanding, the technical solutions of the embodiments of this invention, or the parts that contribute to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as mobile storage devices, ROM, RAM, magnetic disks, or optical disks.

Claims

1. A spindle dynamic balancing test method based on intelligent sensors, characterized in that, include: Real-time acquisition and preprocessing of radial vibration data of the spindle under test yields real-time spindle frequency, rotational frequency, and spindle amplitude. Based on the real-time spindle frequency, rotation frequency and spindle amplitude, the comprehensive vibration score is calculated, the comprehensive vibration score curve is plotted and the predicted comprehensive score is predicted after a preset time period. Establish a preset sample library, acquire and analyze the historical operating data of each spindle sample in the preset sample library, and determine the voltage fluctuation range corresponding to each spindle sample. When the predicted comprehensive score is not within the preset comprehensive score range, spindle dynamic balance correction is performed. If there is a spindle sample in the preset sample library that meets the preset sample requirements, the electric field voltage is adjusted based on the corresponding voltage fluctuation range. If there is no spindle sample in the preset sample library that meets the preset sample requirements, the predicted comprehensive score is analyzed to determine the voltage increase / decrease state and the basic voltage adjustment unit. The electric field voltage is adjusted according to the voltage increase / decrease state and the voltage base adjustment unit, and the real vibration data of the spindle under test is collected in real time. The correction coefficient is determined based on the real vibration data. The voltage base adjustment unit is corrected according to the correction factor, and the electric field voltage is adjusted based on the corrected voltage base adjustment unit; The temperature of the spindle under test is collected in real time, and the spindle is adjusted when the temperature reaches the preset high temperature value.

2. The spindle dynamic balancing test method based on intelligent sensors according to claim 1, characterized in that, The real-time acquisition and preprocessing of the radial vibration data of the spindle under test to obtain the real-time spindle frequency, rotational frequency, and spindle amplitude includes: The vibration data of the spindle under test is collected in real time by a vibration sensor, and the vibration data of the spindle under test is converted into frequency domain data by frequency domain conversion. Extract frequency features from the frequency domain data, including real-time spindle frequency, rotation frequency, and spindle amplitude.

3. The spindle dynamic balancing test method based on intelligent sensors according to claim 1, characterized in that, The process of calculating a comprehensive vibration score based on the real-time spindle frequency, rotation frequency, and spindle amplitude, plotting the comprehensive vibration score curve, and predicting the predicted comprehensive score after a preset time period includes: Calculate the difference between the spindle frequency and the rotational frequency; The comprehensive vibration score is calculated based on the difference between the spindle frequency and the rotation frequency and the corresponding spindle amplitude, according to a preset weight. Based on the comprehensive vibration score, a comprehensive vibration score curve is plotted with the comprehensive vibration score on the vertical axis and time on the horizontal axis. The predicted comprehensive score is predicted after a preset time period based on the trend of the comprehensive vibration score curve.

4. The spindle dynamic balancing test method based on intelligent sensors according to claim 1, characterized in that, The process of establishing a preset sample library, acquiring and analyzing historical operating data for each spindle sample within the preset sample library, and determining the voltage fluctuation range corresponding to each spindle sample includes: Establish a preset sample library and acquire historical operating data for each spindle sample in the preset sample library, including spindle sample information, operating environment, real-time vibration data and corresponding real-time electric field voltage; The corresponding real-time sample comprehensive score is calculated based on the real-time vibration data of each spindle sample. The real-time sample comprehensive score corresponding to each spindle sample is analyzed, and the electric field voltage corresponding to the spindle sample whose real-time sample comprehensive score is within the preset comprehensive score range is added to the electric field voltage sequence. The maximum and minimum values ​​in the electric field voltage sequence corresponding to each master shaft sample are selected to form the voltage fluctuation range for each master shaft sample.

5. The spindle dynamic balancing test method based on intelligent sensors according to claim 4, characterized in that, When the predicted comprehensive score is not within the preset comprehensive score range, spindle dynamic balancing correction is performed. If a spindle sample that meets the preset sample requirements exists in the preset sample library, the electric field voltage is adjusted based on the corresponding voltage fluctuation range, including: Based on the spindle sample information and operating environment in the preset sample library, if there is a spindle sample that meets the preset sample requirements, the voltage fluctuation range corresponding to the spindle sample is selected as the standard voltage range of the spindle to be tested. According to the standard voltage range, the electric field voltage is gradually adjusted to the standard voltage range according to the preset adjustment unit.

6. The spindle dynamic balancing test method based on intelligent sensors according to claim 4, characterized in that, The analysis of the predicted comprehensive score to determine the voltage increase / decrease state and the basic voltage adjustment unit includes: If the predicted comprehensive vibration score is greater than the maximum value of the preset comprehensive score range, then the voltage increase / decrease state is to increase the electric field voltage; If the predicted comprehensive vibration score is less than the minimum value of the preset comprehensive score interval, the comprehensive vibration score curve is analyzed, and the average value of the comprehensive vibration score change rate corresponding to the predicted comprehensive score time and the first three monitoring points is calculated. If the average value of the comprehensive vibration score change rate is less than the preset change rate value, the voltage increase / decrease state is to decrease the voltage. The predicted comprehensive score is analyzed, and the difference e between the predicted comprehensive vibration score and the maximum value of the preset comprehensive vibration score interval and the difference f between the predicted comprehensive vibration score and the minimum value of the preset comprehensive vibration score interval are calculated respectively. Based on the difference e between the predicted comprehensive vibration score and the maximum value of the preset comprehensive vibration score interval, and the difference f between the predicted comprehensive vibration score and the minimum value of the preset comprehensive vibration score interval, the voltage base adjustment unit is determined according to the preset adjustment unit determination method, including the voltage base adjustment unit when increasing the electric field voltage and the voltage base adjustment unit when decreasing the electric field voltage.

7. The spindle dynamic balancing test method based on intelligent sensors according to claim 1, characterized in that, The process involves adjusting the electric field voltage based on the voltage increase / decrease state and the basic voltage adjustment unit, and collecting real vibration data of the spindle under test in real time. Based on the real vibration data, a correction coefficient is determined, including: The electric field voltage is adjusted according to the voltage increase / decrease state and the voltage base adjustment unit. During the adjustment process, real vibration data is collected in real time and the real vibration score is calculated. The real change curve of the real vibration score over time is plotted. Based on the voltage basic adjustment unit, historical data is obtained and an ideal comprehensive score change curve is plotted according to a preset curve plotting method; The absolute value of the difference between the area enclosed by the two curves when the ideal comprehensive score change curve is below the actual change curve and the area enclosed by the two curves when the ideal comprehensive score change curve is above the actual change curve during the voltage regulation period is used as the first difference value M. When the first difference M is greater than the threshold, the voltage regulation unit is corrected. Calculate the second difference A between the ordinate of the actual change curve at the time node corresponding to the first difference M being greater than the threshold and the ordinate of the curve corresponding to the predicted comprehensive vibration score at the time node; Based on the actual change curve, calculate the rate of change of the comprehensive vibration score V1 at the corresponding time node when the first difference M is greater than the threshold. Based on the comprehensive vibration score change rate V1 and the second difference A, the adjusted comprehensive vibration score change rate V2 is calculated as follows: V2 = V1 + A / t; Where t is the difference between the preset correction time and the time node corresponding to the first difference M being greater than the threshold; Based on the adjusted rate of change of the comprehensive vibration score V2, the correction coefficient is determined.

8. The spindle dynamic balancing test method based on intelligent sensors according to claim 7, characterized in that, The step of correcting the voltage base adjustment unit according to the correction factor and adjusting the electric field voltage based on the corrected voltage base adjustment unit includes: Calculate the product of the correction factor and the voltage base adjustment unit to obtain the corrected voltage base adjustment unit; The electric field voltage between the time node corresponding to the first difference M being greater than the threshold and the preset correction time is adjusted according to the corrected voltage base adjustment unit, and the electric field voltage corresponding to the preset correction time is continuously output as the final voltage.

9. The spindle dynamic balancing test method based on intelligent sensors according to claim 1, characterized in that, The temperature of the spindle under test is acquired in real time, and when the temperature reaches a preset high temperature value, the spindle under test is adjusted, including: A temperature sensor is used to collect the temperature in real time. When the temperature reaches the preset high temperature value, the temperature protection mechanism is activated, the spindle speed is reduced to the first preset speed value, and the heat dissipation system is activated. When the temperature drops to the preset low temperature value, the cooling system is turned off and the spindle speed is increased to the second preset speed value.

10. A spindle dynamic balancing test system based on intelligent sensors, used to implement the spindle dynamic balancing test method based on intelligent sensors as described in any one of claims 1-9, characterized in that, include: The data acquisition module is used to acquire the radial vibration data of the spindle under test in real time and perform preprocessing to obtain the real-time spindle frequency, rotational frequency and spindle amplitude. The first data analysis module is used to calculate the comprehensive vibration score based on the real-time spindle frequency, rotation frequency and spindle amplitude, draw the comprehensive vibration score curve and predict the predicted comprehensive score after a preset time period. The sample testing module is used to establish a preset sample library, acquire and analyze the historical operating data of each spindle sample in the preset sample library, and determine the voltage fluctuation range corresponding to each spindle sample. The first voltage adjustment module performs spindle dynamic balance correction when the predicted comprehensive score is not within the preset comprehensive score range. If there is a spindle sample in the preset sample library that meets the preset sample requirements, the electric field voltage is adjusted based on the corresponding voltage fluctuation range. The second data analysis module analyzes the predicted comprehensive score if there is no spindle sample in the preset sample library that meets the preset sample requirements, and determines the voltage increase / decrease status and the basic voltage adjustment unit. The electric field voltage is adjusted according to the voltage increase / decrease state and the voltage base adjustment unit, and the real vibration data of the spindle under test is collected in real time. The correction coefficient is determined based on the real vibration data. The second voltage regulation module is used to correct the voltage base regulation unit according to the correction coefficient and to regulate the electric field voltage based on the corrected voltage base regulation unit. The temperature monitoring module is used to collect the temperature of the spindle under test in real time. When the temperature reaches the preset high temperature value, the spindle under test is adjusted.

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