Knife breakage recognition method and system based on ultrasonic generator and electronic device

Abstract

This invention relates to the field of ultrasonic control technology and discloses a method, system, and electronic device for identifying broken tools based on an ultrasonic generator. The method involves pre-simulating the operation of an ultrasonic generator driving an ultrasonic machining system to obtain the current change trend of the ultrasonic generator and obtain reference values ​​corresponding to multiple step nodes. The ultrasonic generator controls the tool of the ultrasonic machining system to begin machining the workpiece according to set operating conditions. The current change of the ultrasonic generator during ultrasonic machining is detected in real time. When a step in current is detected, the step node is compared with the reference value, and if the two do not match, a broken tool fault is identified in the ultrasonic machining system. The ultrasonic generator then controls the ultrasonic machining system to stop operating. The method of this invention is simple, reliable, and easy to implement, requiring no additional detection module and directly identifying tool breakage.

Description

Technical Field

[0001] This invention relates to the field of machining technology, and more specifically, to a method and system for identifying broken tools based on an ultrasonic generator. Background Technology

[0002] Ultrasonic vibration machining utilizes ultrasonic vibrations to create high-frequency impacts on the workpiece in a specific direction for processing. It can be combined with milling, drilling, polishing, and welding processes, significantly improving machining performance. Ultrasonic vibration machining can reduce cutting forces and heat during processing, reduce tool wear, and improve the surface quality of the machined material. It is widely used for hard and brittle materials, vibrating materials, and other difficult-to-machine materials, especially in the aerospace, automotive, and 3C industries.

[0003] In high-volume ultrasonic machining, if cutting tools suffer severe wear or breakage and are not replaced in time, it can lead to workpiece scrap, damage to the tool holder or machine tool, or even personal injury, and will also affect production capacity and machining quality. Furthermore, due to the large-scale production and limited human intervention, it is crucial to promptly detect and address tool breakage to ensure machining safety and efficiency. Summary of the Invention

[0004] The purpose of this invention is to address the technical problems existing in the prior art by providing a method and system for identifying broken tools based on an ultrasonic generator, which can reliably identify tool breakage.

[0005] To address the problems mentioned above, the technical solution adopted by this invention is as follows:

[0006] This invention provides a method for identifying broken blades based on an ultrasonic generator, the specific steps of which include the following:

[0007] Step S1: Simulate the operation of the ultrasonic generator driving the ultrasonic processing system in advance, obtain the current change trend of the ultrasonic generator, and obtain the reference values ​​corresponding to multiple step nodes;

[0008] Step S2: The ultrasonic generator controls the cutting tool of the ultrasonic machining system to start machining the workpiece according to the set working conditions;

[0009] Step S3: Real-time detection of current changes in the ultrasonic generator during ultrasonic processing;

[0010] Step S4: When a step current is detected, the step node is compared with the reference value, and if the two do not match, it is determined that the ultrasonic processing system has a tool breakage fault.

[0011] Step S5: The ultrasonic generator controls the ultrasonic processing system to stop working.

[0012] Furthermore, the reference values ​​corresponding to the step nodes include the step type of current change and the reference time points corresponding to different step types.

[0013] Furthermore, the step of pre-acquiring the current change trend to obtain reference values ​​corresponding to multiple step nodes specifically includes:

[0014] Step S11: Collect the current of the ultrasonic generator during the ultrasonic processing;

[0015] Step S12: Determine whether the collected current has a step change. If it has, proceed to step S13; if it has not, return to step S11.

[0016] Step S13: Determine whether the current step is the first occurrence. If yes, store the step type and record the current time point as the reference zero point, and execute step S15; otherwise, execute step S14.

[0017] Step S14: Store the step type, calculate the time difference between the current current step occurrence time and the reference zero point, and use it as the reference point;

[0018] Step S15: Determine whether the processing is complete. If yes, end the process; otherwise, return to step S11.

[0019] Furthermore, step S4 specifically includes:

[0020] Step S41: Determine whether the detected current has a step. If yes, proceed to step S42; otherwise, return to step S3.

[0021] Step S42: Determine whether the current current step is the first occurrence. If yes, proceed to step S43; otherwise, calculate the time point of the current current step and proceed to step S44.

[0022] Step S43: Compare the current step type and the time point of occurrence with the reference zero point to determine whether they match. If they match, return to step S3; otherwise, proceed to step S46.

[0023] Step S44: Compare the time point of the current step with the reference point to determine if they match. If they match, proceed to step S45; otherwise, proceed to step S46.

[0024] Step S45: Determine whether the type of current step matches the type of reference point. If they match, return to step S3; otherwise, proceed to step S46.

[0025] Step S46: Confirm that the ultrasonic machining system has a broken tool malfunction.

[0026] Furthermore, the reference value for each step node is set to [Step_Xn t0], where t0 is the time when the step node occurs, and the step type of the step node is... The reference values ​​of all step nodes are given by a node matrix A of 2×n.

[0027] Furthermore, the specific steps of the broken knife identification method include the following:

[0028] The ultrasonic generator drives the ultrasonic processing system multiple times in advance to obtain multiple node matrices A2, A3...An. The special cases are removed and the average value is calculated to obtain the reference matrix A0.

[0029] The reference matrix A0 is copied in advance to obtain the initial matrix B = A0;

[0030] The ultrasonic generator controls the cutting tool of the ultrasonic machining system to begin machining the workpiece according to the set working conditions;

[0031] The current change of the ultrasonic generator during ultrasonic processing is detected in real time, and the initial matrix B is updated in real time according to the current change to obtain the processing matrix B1.

[0032] When a step change in current is detected, the processing matrix B1 is matched and compared with the initial matrix B to obtain the difference matrix C = B1 - B;

[0033] If the difference matrix contains a non-zero value, it is determined that the ultrasonic processing system has a tool breakage fault.

[0034] The ultrasonic generator controls the ultrasonic processing system to stop working.

[0035] The present invention also provides a broken knife identification system based on an ultrasonic generator, the system specifically comprising:

[0036] Simulation acquisition module: used to simulate the operation of the ultrasonic generator driving the ultrasonic processing system in advance, acquire the current change trend of the ultrasonic generator, and obtain the reference values ​​corresponding to multiple step nodes;

[0037] Machining control module: Used by the ultrasonic generator to control the cutting tool of the ultrasonic machining system to start machining the workpiece according to the set working conditions;

[0038] Real-time detection module: used to detect the current changes of the ultrasonic generator during ultrasonic processing in real time;

[0039] Comparison and judgment module: When a step current is detected, the step node is compared with the reference value, and if the two do not match, it is determined that the ultrasonic processing system has a tool breakage fault.

[0040] Stop control module: Used to control the ultrasonic processing system to stop working.

[0041] The present invention also provides an electronic device, comprising:

[0042] At least one processor; and

[0043] A memory communicatively connected to the at least one processor; wherein,

[0044] The memory stores instructions that can be executed by the at least one processor, which are then executed by the at least one processor to enable the at least one processor to perform the ultrasonic generator-based broken knife identification method according to any one of claims 1 to 4.

[0045] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0046] This invention pre-stores reference values ​​corresponding to multiple step nodes. During actual processing, when a current step is detected, the step node is compared with the reference value. If the two do not match, a tool breakage fault is identified. The method is simple, reliable, and easy to implement. It can achieve the function of tool breakage identification without additional detection modules, thereby ensuring the working efficiency of the ultrasonic processing system. Attached Figure Description

[0047] To more clearly illustrate the solutions in this invention, a brief introduction to the accompanying drawings used in the description of the embodiments will be provided below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without any creative effort. Wherein:

[0048] Figure 1 This is an overall flowchart of the ultrasonic generator-based broken knife identification method of the present invention.

[0049] Figure 2 This is a flowchart illustrating the process of pre-obtaining the current change trend in this invention.

[0050] Figure 3 This is a processing example and a schematic diagram of current changes in the ultrasonic processing system of this invention.

[0051] Figure 4 This is a flowchart for determining the broken tool fault in this invention.

[0052] Figure 5 This is a flowchart illustrating an example of determining a broken tool fault in this invention.

[0053] Figure 6 This is a flowchart illustrating the second instance of determining a broken tool fault in this invention.

[0054] Figure 7 This is a schematic diagram of the ultrasonic generator-based broken knife identification system of the present invention.

[0055] Figure 8 This is a hardware structure diagram of the ultrasonic generator-based broken knife identification method of the present invention. Detailed Implementation

[0056] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. For example, terms such as “length,” “width,” “upper,” “lower,” “left,” “right,” “front,” “rear,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer” indicate orientations or positions based on the orientations or positions shown in the accompanying drawings and are for ease of description only, and should not be construed as limiting the technical solution.

[0057] The terms "comprising" and "having," and any variations thereof, in the specification, claims, and accompanying drawings of this invention are intended to cover non-exclusive inclusion; the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish different objects, not to describe a particular order. In the specification, claims, and accompanying drawings of this invention, when an element is referred to as "fixed to," "mounted to," "disposed of," or "connected to" another element, it may be directly or indirectly located on that other element. For example, when an element is referred to as "connected to" another element, it may be directly or indirectly connected to that other element.

[0058] Furthermore, the reference to "embodiment" herein means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0059] See Figure 1 As shown, this invention provides a method for identifying broken knives based on an ultrasonic generator. The specific steps of this method include the following:

[0060] Step S1: Simulate the operation of the ultrasonic generator driving the ultrasonic processing system in advance, obtain the current change trend of the ultrasonic generator, and obtain the reference values ​​corresponding to multiple step nodes;

[0061] Furthermore, in step S1, the current change trend of the ultrasonic generator is obtained, and the reference value includes the step type and the reference time point corresponding to different step types.

[0062] Specifically, when an ultrasonic generator drives an ultrasonic machining system (including ultrasonic tool holders or ultrasonic spindles, cutting tools, etc.) to perform ultrasonic machining on a workpiece, it consumes a certain amount of current. This current changes with the machining load (pressure). For example, changes in the depth of cut or feed rate will cause changes in the load (pressure), which in turn will cause changes in the current. When the tool breaks, it is equivalent to the tool leaving the workpiece surface. Changes in the load will cause a step change in the current. Therefore, the current change trend can be obtained in advance and the step node can be stored. In actual machining, it can be used as a reference value for tool breakage identification.

[0063] Step S2: The ultrasonic generator controls the cutting tool of the ultrasonic machining system to start machining the workpiece according to the set working conditions.

[0064] Step S3: Real-time detection of current changes in the ultrasonic generator during ultrasonic processing;

[0065] Specifically, in actual processing tests, it was observed that as long as the force of the tool changes, the current of the ultrasonic generator will change accordingly. Therefore, once the processing flow of a specific workpiece is determined, the trend of force change is basically fixed throughout the entire processing process, and the change of current is also fixed. Thus, the abnormal condition of the tool during the processing can be judged indirectly by detecting the trend of current change in the ultrasonic generator.

[0066] Step S4: When a step current is detected, the step node is compared with the reference value. If the two do not match, it is determined that the ultrasonic processing system has a broken tool fault.

[0067] Specifically, due to force changes during machining, such as when the tool is lowered, reaches a certain inflection point, or is withdrawn from the workpiece, a step change in current will occur. Since the machining process is the same for each workpiece, the type and relative time of the step change at each step node are roughly the same. Therefore, when a step node occurs, it can be compared with a pre-stored reference value. If the time of occurrence does not match, or the type of step change does not match, it can be determined that the tool has broken.

[0068] Step S5: The ultrasonic generator controls the ultrasonic machining system to stop working and replaces the faulty tool.

[0069] In this embodiment of the invention, by pre-simulating and obtaining the current change trend of the ultrasonic generator, reference values ​​corresponding to multiple step nodes are obtained. In actual processing, when a current step is detected, the step node is compared with the reference value, and if the two do not match, it is determined that a tool breakage fault has occurred. The method is simple, reliable and easy to implement, without the need for an additional detection module. All functions are integrated into the ultrasonic generator, which is equivalent to the ultrasonic generator having the function of detecting tool breakage.

[0070] For further details, please refer to [link / reference]. Figure 2 As shown, the step of pre-acquiring the current change trend to obtain reference values ​​corresponding to multiple step nodes specifically includes:

[0071] Step S11: Collect the current of the ultrasonic generator during the ultrasonic processing;

[0072] Step S12: Determine whether the collected current has a step change. If it has, proceed to step S13; if it has not, return to step S11.

[0073] Step S13: Determine whether the current step is the first occurrence. If yes, store the step type and record the current time as the reference zero point, and execute step S15; otherwise, execute step S14.

[0074] Step S14: Store the current step type, calculate the time difference between the current step occurrence time and the reference zero point, and use it as the reference point;

[0075] Specifically, during ultrasonic processing, multiple current steps may occur depending on the operating conditions. The pre-stored reference values ​​include the types of current steps and the times when they occur, i.e., the first occurrence, the second occurrence, the third occurrence…thenth occurrence of the current step, with corresponding times at reference zero, reference point 1, reference point 2…reference point n, respectively. In other words, the reference time is either a reference zero or reference points (1, 2…n). Therefore, if the current step is the first occurrence, it is directly compared with the reference zero; if it is not the first occurrence, the relative time between the current current step and the first occurrence needs to be calculated and compared with the reference value at the corresponding reference point, thus ensuring the overall reliability and accuracy of the method.

[0076] Step S15: Determine whether the processing is complete. If yes, end the process; otherwise, return to step S11.

[0077] In this invention, Figure 4 (a) shows an example of an ultrasonic machining system processing a workpiece. The arrows indicate the machining direction, and the upper surface contour represents the area that was cut away during the machining process. Four step current nodes were detected during the entire machining process. Figure 4(b) shows the corresponding current curves, where the first is the rising edge node for the tool's downward movement, the second is the rising edge node for increasing the depth of cut, the third is the falling edge node for restoring the depth of cut, and the last is the falling edge node for the tool leaving the workpiece. Therefore, the types (i.e., rising edge or falling edge) corresponding to the four current step nodes can be pre-stored, and the relative time of the step node occurrence can be recorded as a reference point for current steps during ultrasonic machining.

[0078] For further details, please refer to [link / reference]. Figure 3 As shown, step S4 specifically includes:

[0079] Step S41: Determine whether the detected current has a step. If yes, proceed to step S42; otherwise, return to step S3.

[0080] Step S42: Determine whether the current current step is the first occurrence. If yes, proceed to step S43; otherwise, calculate the time point of the current current step and proceed to step S44.

[0081] Step S43: Compare the time point of the current step with the reference zero point to determine whether they match. If they match, return to step S3; if they do not match, proceed to step S46.

[0082] Step S44: Compare the time point of the current step with the reference point to determine if they match. If they match, proceed to step S45; otherwise, proceed to step S46.

[0083] Step S45: Determine whether the type of current step matches the type of reference point. If they match, return to step S3; otherwise, proceed to step S46.

[0084] Step S46: Confirm that the ultrasonic machining system has a broken tool malfunction.

[0085] Specifically, such as Figure 4 As shown, the relative time and node type of each step node are pre-stored as reference values. Specifically, time t0 can be considered the reference zero point, and t1, t2, and t3 are the times relative to the reference zero point. By storing the node time information and node type, the actual current step node can be compared with the reference value during ultrasonic processing to determine the tool breakage situation.

[0086] Furthermore, the reference value for each step node is set to [Step_Xn t0], where t0 is the time when the step node occurs, and the step type of the step node is... The reference values ​​of all step nodes are given by a node matrix A of 2×n.

[0087] Furthermore, the specific steps of the broken knife identification method include the following:

[0088] Step a: Simulate the ultrasonic generator driving the ultrasonic processing system multiple times in advance to obtain multiple node matrices A2, A3...An, remove the special case matrices, and calculate the average value to obtain the reference matrix A0;

[0089] Specifically, to reduce the influence of random factors, the ultrasonic processing system can be pre-driven several times to eliminate special cases (those with step types and occurrence times that are significantly different from other matrices), and then the average value can be calculated to obtain the reference matrix. This facilitates subsequent identification and detection of broken blades and improves detection accuracy.

[0090] Step b: Before processing, copy and store the reference matrix A0 to obtain the initial matrix B, i.e., B = A0;

[0091] Step c: The ultrasonic generator controls the cutting tool of the ultrasonic machining system to start machining the workpiece according to the set working conditions;

[0092] Step d: Real-time detection of the current change of the ultrasonic generator during ultrasonic processing, and real-time update of the initial matrix B based on the current change to obtain the processing matrix B1;

[0093] Step e: When a step current is detected, the processing matrix B1 is matched and compared with the initial matrix B to obtain the difference matrix C = B1 - B;

[0094] Step f: If the difference matrix has a non-zero value, it is determined that the ultrasonic processing system has a tool breakage fault;

[0095] Step g: The ultrasonic generator controls the ultrasonic processing system to stop working.

[0096] Specifically, during the machining process, if the machining matrix B1 is the same as the initial matrix B, then all values ​​of the difference matrix C are 0; if the difference matrix C has a non-zero value, it means that the machining matrix B1 has changed as the machining continues, and this can be used to determine that the tool has broken.

[0097] For example, if we obtain the difference matrix This indicates a mismatch in the step type of the second step node, which can be identified as a broken tool fault. If the difference matrix is ​​obtained... This indicates that the third step node appears too early, i.e., a mismatch, which can be identified as a broken tool fault.

[0098] In this embodiment, the reference values ​​of multiple step nodes are represented by a matrix, and an initial matrix B is obtained by pre-copying and storing it. During the processing, the initial matrix B is updated in real time to obtain the processing matrix B1. The difference matrix is ​​used to determine whether a tool breakage fault has occurred. The method is simple, reliable and easy to implement, and it is easy to identify tool breakage faults, ensuring processing reliability and safety.

[0099] In one embodiment of the present invention, Figure 5 The diagram shows a comparison between the actual current step node and the reference node. The specific process for determining the broken blade is as follows:

[0100] 1) The current of the ultrasonic generator was detected in real time, and a step current was detected at Pt0;

[0101] 2) If it is confirmed that the current step is the first occurrence, then compare the Pt0 node with the reference zero point Rt0;

[0102] 3) If the current step type at node Pt0 is rising edge and the current step occurs at the same time as the reference zero point Rt0, it means that Pt0 is consistent with the reference zero point Rt0.

[0103] 4) A current step was detected at Pt1 and it was not the first time it had occurred. Calculate the relative time between the current step at node Pt1 and node Pt0.

[0104] 5) If the relative time of node Pt1 is consistent with that of reference point Rt1 and the current step type is rising edge, it means that node Pt1 is consistent with reference point R1.

[0105] 6) If a current step is detected at node Pt2 and it is not the first time it has occurred, calculate the relative time between the current step at node Pt2 and node Pt0.

[0106] 7) If Pt2 < Rt2, it can be determined that the tool left the workpiece prematurely, and the tool is considered to have broken.

[0107] In another embodiment of the present invention, Figure 6 The diagram shows a comparison between the actual current step node and the reference value. The specific process for determining the broken blade is as follows:

[0108] 1) The current of the ultrasonic generator was detected in real time, and a step current was detected at Qt0;

[0109] 2) If it is confirmed that the current step is the first occurrence, then compare the Qt0 node with the reference zero point Rt0;

[0110] 3) If the current step type of node Qt0 is rising edge and the current step occurs at the same time as the reference zero point Rt0, then it means that node Qt0 matches the reference zero point Rt0.

[0111] 4) If a current step is detected at node Qt1 and it is not the first time it has occurred, calculate the relative time between the current step at node Qt1 and node Qt0.

[0112] 5) If the relative time of node Qt1 is consistent with that of reference point Rt1, but the current step type is a falling edge, it means that node Qt1 does not match reference point R1.

[0113] 6) It can be determined that the tool left the workpiece prematurely, and thus the tool is considered broken.

[0114] In this embodiment of the invention, by detecting the current of the ultrasonic generator in real time, and comparing the step node with the reference value when a step in the current is detected, it is possible to reliably and efficiently determine whether a broken blade fault has occurred.

[0115] See Figure 7 As shown, the present invention also provides a broken knife identification system based on an ultrasonic generator, which specifically includes the following:

[0116] Simulation acquisition module: used to simulate the operation of the ultrasonic generator driving the ultrasonic processing system in advance, acquire the current change trend of the ultrasonic generator, and obtain the reference values ​​corresponding to multiple step nodes;

[0117] Machining control module: Used by the ultrasonic generator to control the cutting tool of the ultrasonic machining system to start machining the workpiece according to the set working conditions;

[0118] Real-time detection module: used to detect the current changes of the ultrasonic generator during ultrasonic processing in real time;

[0119] Comparison and judgment module: When a step current is detected, the step node is compared with the reference value, and if the two do not match, it is determined that the ultrasonic processing system has a tool breakage fault.

[0120] Stop control module: Used to control the ultrasonic processing system to stop working.

[0121] It should be noted that the ultrasonic generator-based broken knife identification system provided in the above embodiments is only illustrated by the division of the functional modules described above. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the system can be divided into different functional modules based on its internal structure to complete all or part of the functions described above. Furthermore, the embodiments of the system and method provided in the above embodiments belong to the same concept, and the specific methods of operation of each module have been described in detail in the method embodiments, and will not be repeated here.

[0122] Based on the ultrasonic generator broken knife identification method, this invention also provides an electronic device, which includes one or more processors and a memory. Taking one processor as an example, the device may also include an input system and an output system.

[0123] Processors, memory, input systems, and output systems can be connected via buses or other means. Figure 8 Taking the example of a connection between China and Israel via a bus.

[0124] Memory, as a non-transitory computer-readable storage medium, can be used to store non-transitory software programs, non-transitory computer-executable programs, and modules. The processor executes various functional applications and data processing of the electronic device by running the non-transitory software programs, instructions, and modules stored in the memory, thereby implementing the processing methods of the above-described embodiments.

[0125] The memory may include a program storage area and a data storage area, wherein the program storage area may store the operating system and application programs required for at least one function; the data storage area may store data, etc. Furthermore, the memory may include high-speed random access memory and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some embodiments, the memory may optionally include memory remotely located relative to the processor, which can be connected to the processing system via a network; examples of such networks include, but are not limited to, the Internet, corporate intranets, local area networks, mobile communication networks, and combinations thereof.

[0126] The input system can receive input digital or character information and generate signal inputs. The output system may include display devices such as a display screen.

[0127] The one or more modules are stored in the memory, and when executed by the one or more processors, they perform any of the methods described above.

[0128] This invention provides a non-transitory (non-volatile) computer storage medium storing computer-executable instructions that can execute any of the above-described method embodiments.

[0129] This invention provides a computer program product, which includes a computer program stored on a non-transitory computer-readable storage medium. The computer program includes program instructions, which, when executed by a computer, cause the computer to perform any of the above-described method embodiments.

[0130] The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of the present invention shall be considered equivalent substitutions and shall be included within the protection scope of the present invention.

Claims

1. A method for identifying broken blades based on an ultrasonic generator, characterized in that: The method includes: Step S1: Simulate the operation of the ultrasonic generator driving the ultrasonic processing system in advance, obtain the current change trend of the ultrasonic generator, and obtain the reference values ​​corresponding to multiple step nodes; Step S2: The ultrasonic generator controls the cutting tool of the ultrasonic machining system to start machining the workpiece according to the set working conditions; Step S3: Real-time detection of current changes in the ultrasonic generator during ultrasonic processing; Step S4: When a step current is detected, the step node is compared with the reference value, and if the two do not match, it is determined that the ultrasonic processing system has a tool breakage fault. Step S5: The ultrasonic generator controls the ultrasonic processing system to stop working.

2. The method for identifying broken blades based on an ultrasonic generator according to claim 1, characterized in that: The reference values ​​corresponding to the step nodes include the step type of current change and the reference time points corresponding to different step types.

3. The method for identifying broken blades based on an ultrasonic generator according to claim 2, characterized in that: The process of pre-observing the current change trend to obtain reference values ​​corresponding to multiple step nodes specifically includes: Step S11: Collect the current of the ultrasonic generator during the ultrasonic processing; Step S12: Determine whether the collected current has a step change. If it has, proceed to step S13; if it has not, return to step S11. Step S13: Determine whether the current step is the first occurrence. If yes, store the step type and record the current time point as the reference zero point, and execute step S15; otherwise, execute step S14. Step S14: Store the step type, calculate the time difference between the current current step occurrence time and the reference zero point, and use it as the reference point; Step S15: Determine whether the processing is complete. If yes, end the process; otherwise, return to step S11.

4. The method for identifying broken blades based on an ultrasonic generator according to claim 3, characterized in that: Step S4 specifically includes: Step S41: Determine whether the detected current has a step. If yes, proceed to step S42; otherwise, return to step S3. Step S42: Determine whether the current current step is the first occurrence. If yes, proceed to step S43; otherwise, calculate the time point of the current current step and proceed to step S44. Step S43: Compare the current step type and the time point of occurrence with the reference zero point to determine whether they match. If they match, return to step S3; otherwise, proceed to step S46. Step S44: Compare the time point of the current step with the reference point to determine if they match. If they match, proceed to step S45; otherwise, proceed to step S46. Step S45: Determine whether the type of current step matches the type of reference point. If they match, return to step S3; otherwise, proceed to step S46. Step S46: Confirm that the ultrasonic machining system has a broken tool malfunction.

5. The method for identifying broken blades based on an ultrasonic generator according to claim 2 or 4, characterized in that: The reference value for each step node is set as [Step_Xn t0], where t0 is the time when the step node occurs, and the step type of the step node is... The reference values ​​of all step nodes are given by a node matrix A of 2×n.

6. The method for identifying broken blades based on an ultrasonic generator according to claim 5, characterized in that: The specific steps of the broken knife identification method include the following: The ultrasonic generator drives the ultrasonic processing system multiple times in advance to obtain multiple node matrices A2, A3...An. The special case matrices are removed and the average value is calculated to obtain the reference matrix A0. The reference matrix A0 is copied in advance to obtain the initial matrix B = A0; The ultrasonic generator controls the cutting tool of the ultrasonic machining system to begin machining the workpiece according to the set working conditions; The current change of the ultrasonic generator during ultrasonic processing is detected in real time, and the initial matrix B is updated in real time according to the current change to obtain the processing matrix B1. When a step change in current is detected, the processing matrix B1 is matched and compared with the initial matrix B to obtain the difference matrix C = B1 - B; If the difference matrix contains a non-zero value, it is determined that the ultrasonic processing system has a broken tool fault. The ultrasonic generator controls the ultrasonic processing system to stop working.

7. A system based on the ultrasonic generator-based broken knife identification method according to any one of claims 1 to 6, characterized in that: The system specifically includes: Simulation acquisition module: used to simulate the operation of the ultrasonic generator driving the ultrasonic processing system in advance, acquire the current change trend of the ultrasonic generator, and obtain the reference values ​​corresponding to multiple step nodes; Machining control module: Used by the ultrasonic generator to control the cutting tool of the ultrasonic machining system to start machining the workpiece according to the set working conditions; Real-time detection module: used to detect the current changes of the ultrasonic generator during ultrasonic processing in real time; Comparison and judgment module: When a step current is detected, the step node is compared with the reference value, and if the two do not match, it is determined that the ultrasonic processing system has a tool breakage fault. Stop control module: Used to control the ultrasonic processing system to stop working.

8. An electronic device, characterized in that: include: At least one processor; as well as A memory communicatively connected to the at least one processor; wherein, The memory stores instructions that can be executed by the at least one processor, which are then executed by the at least one processor to enable the at least one processor to perform the ultrasonic generator-based broken knife identification method according to any one of claims 1 to 4.

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