An intelligent management system for a power tool output shaft production line

Abstract

This invention discloses an intelligent management system for a power tool output shaft production line, relating to the field of power tool production management technology. It includes a cycle time collaborative control terminal, a precision compensation monitoring terminal, a wear early warning analysis terminal, and a full-process traceability management terminal connected to a central control matrix via industrial Ethernet. The cycle time collaborative control terminal adjusts the conveyor speed based on the deviation of the processing load; the precision compensation monitoring terminal achieves precision feedback compensation through 3D scanning; the wear early warning analysis terminal uses a signal decoupling algorithm for health assessment and early warning; and the full-process traceability management terminal constructs a traceability database through identification codes. This application enables deep coupling between flow and cycle time, improves the consistency of processing precision and the scientific nature of maintenance, ensures the integrity of the quality data chain, and enhances the self-healing capability of the production line.

Description

Technical Field

[0001] This invention relates to the field of power tool production management technology, and in particular to an intelligent management system for power tool output shaft production lines. Background Technology

[0002] As a core component of the transmission system, the output shaft of a power tool directly determines its service life and operational stability through its machining accuracy, surface hardness, and assembly quality. With the digital transformation of the manufacturing industry, building an intelligent management system integrating sensing, analysis, and control has become a crucial path to improving the automation level of output shaft production lines. Such systems typically integrate key processes such as heat treatment, precision grinding, and automated assembly. Through real-time collection and analysis of data from various dimensions during production, they aim to achieve full lifecycle traceability of workpieces and closed-loop optimization of process parameters, ensuring transparency and efficiency in the production process.

[0003] Currently, due to the complex processes involved in the production of output shafts, such as rough machining, heat treatment, and fine grinding, the existing management system has room for optimization in matching material flow with processing cycle time when monitoring the production line status in real time. When material accumulates or idles at local workstations on the production line, the system's dynamic adjustment of the overall line cycle time is delayed, and the real-time feedback and compensation mechanism for processing accuracy still needs improvement.

[0004] Therefore, an intelligent management system for the output shaft production line of power tools is proposed to solve the above problems. Summary of the Invention

[0005] The main objective of this invention is to provide an intelligent management system for power tool output shaft production lines to solve the problems mentioned in the background.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: an intelligent management system for the output shaft production line of power tools, including a cycle time coordination control terminal, a precision compensation monitoring terminal, a wear early warning analysis terminal, and a full-process traceability management terminal. The cycle time coordination control terminal, the precision compensation monitoring terminal, the wear early warning analysis terminal, and the full-process traceability management terminal communicate bidirectionally via an industrial Ethernet bus, and each terminal is electrically connected to a central control matrix.

[0007] The cycle time coordination control terminal obtains real-time material distribution data through the material sensing array deployed at each workstation of the output shaft production line, and calculates the processing load deviation of each processing node in combination with the preset process standard duration. By adjusting the operating frequency of the conveying drive device, the material flow rate between each workstation is kept synchronized with the real-time processing progress.

[0008] The precision compensation monitoring terminal collects the geometric features of the output shaft after processing using a high-precision laser scanner, converts the features into a set of spatial coordinate points, compares them with a standard model point cloud, calculates the real-time deviation vector of the processing parameters, and converts the deviation vector into a compensation command that is fed back to the actuator of the CNC machining unit. The actuator adjusts the feed rate according to the compensation command.

[0009] The wear warning analysis terminal collects the operating signals of the processing equipment through vibration sensors and electromagnetic sensors, uses a signal decoupling algorithm to eliminate environmental vibration and electromagnetic interference, extracts the wear characteristic frequencies of key components, and calculates the equipment health index based on the amplitude changes of the wear characteristic frequencies. When the health index is lower than the preset safety threshold, the system triggers a maintenance warning signal.

[0010] The full-process traceability management terminal etches a unique identification code at the end of the output shaft and automatically associates processing parameters, environmental parameters and test data at each processing node to build a multi-dimensional quality traceability database, realizing a closed-loop data chain for the entire life cycle of the output shaft from raw material feeding to finished product warehousing.

[0011] The cycle time coordination control terminal includes a workstation load monitoring module, a flow scheduling module, and a drive control module.

[0012] The workstation load monitoring module includes a sensing unit, a timing unit, and a load calculation unit. The sensing unit acquires the input and output level signals of the output shaft through infrared through-beam sensors symmetrically arranged at the entrance and exit of each processing workstation. The timing unit records the time interval between two adjacent input and output level signals as the actual processing time. The load calculation unit calculates the processing load deviation based on the actual processing time and the preset standard processing time, using the following formula:

[0013] ;

[0014] in, Indicates the deviation of processing load. Indicates the first The actual processing time for each workstation. Indicates the first The preset standard processing time for each workstation. This indicates the total number of workstations.

[0015] The flow scheduling module includes a rate calculation unit and a flow instruction unit; the rate calculation unit dynamically calculates the target operating rate of the conveying device based on the processing load deviation; the flow instruction unit converts the target operating rate into a pulse width modulation signal and sends it to the drive control module.

[0016] The drive control module includes a frequency converter and a conveyor motor. The frequency converter adjusts the speed of the conveyor motor according to the pulse width modulation signal, thereby changing the linear speed of the conveyor belt.

[0017] The accuracy compensation monitoring terminal includes a three-dimensional scanning module, a deviation calculation module, and a command feedback module.

[0018] The three-dimensional scanning module includes a laser emitting unit, an image acquisition unit, and a coordinate construction unit. The laser emitting unit projects structured light onto the surface of the output shaft, the image acquisition unit acquires the structured light image modulated by the surface topography of the object, and the coordinate construction unit constructs a set of three-dimensional coordinate points on the surface of the output shaft using the principle of triangulation.

[0019] The deviation calculation module is used to calculate the deviation between the actual size and the standard size of the output shaft. The specific steps are as follows:

[0020] Step 1: Set the central axis of the standard model as the reference axis, establish a spatial rectangular coordinate system, and normalize the collected three-dimensional coordinate point set;

[0021] Step 2: Fit the center coordinates and radius of the key section of the output shaft using the least squares method, calculate the difference between the actual radius and the standard radius, and obtain the radial deviation value;

[0022] Step 3: Calculate the straightness deviation of the axis. The calculation formula is as follows:

[0023] ;

[0024] in and They represent the first The center point of each section relative to the reference axis is shaft and Offset in the axial direction Indicates the number of cross-sectional samples.

[0025] The instruction feedback module includes a deviation vectorization unit and a compensation instruction generation unit. The deviation vectorization unit synthesizes the radial deviation value and the straightness deviation into a spatial deviation vector. The compensation instruction generation unit calculates the CNC machine tool compensation amount based on the spatial deviation vector and sends the compensation amount to the CNC system in the form of a data packet.

[0026] The wear warning analysis terminal includes a signal acquisition module, an interference suppression module, and a health assessment module.

[0027] The signal acquisition module includes an accelerometer and a current transformer. The accelerometer is installed at the bearing housing of the grinding machine spindle and is used to acquire spindle vibration signals. The current transformer is coupled to the power supply line of the spindle motor and is used to acquire spindle current signals.

[0028] The interference suppression module includes a filtering unit and a decoupling unit; the filtering unit uses a bandpass filter to filter out environmental noise outside the preset frequency range; the decoupling unit uses an independent component analysis algorithm to separate the inherent vibration signal of the equipment from the environmental interference signal in the vibration signal.

[0029] The health assessment module includes a feature extraction unit and an early warning determination unit. The feature extraction unit uses Fast Fourier Transform to obtain the power spectral density of the signal and extracts the characteristic frequency amplitudes related to bearing wear. The early warning determination unit calculates the equipment health index based on the characteristic frequency amplitudes, using the following formula:

[0030] ;

[0031] Where $H$ represents the health index, This represents the vibration amplitude under standard conditions. This represents the vibration amplitude collected in real time. This represents the motor current value under standard conditions. This represents the real-time collected motor current value. and This indicates the preset weighting coefficient.

[0032] The end-to-end traceability management system includes an identification code etching module, a process association module, and a traceability index module.

[0033] The identification code etching module includes a laser machine and a vision verification unit. The laser machine etches a QR code containing batch information on the non-mating end face of the output shaft, and the vision verification unit reads and verifies the etched QR code to ensure the uniqueness and readability of the identification.

[0034] The process association module includes a data acquisition gateway and a timestamp association unit. The data acquisition gateway acquires the temperature curve of the heat treatment furnace, the feed speed of the fine grinding machine, the coolant flow rate, and the ambient temperature and humidity data in real time through the fieldbus. The timestamp association unit binds the above data with the timestamp corresponding to the identification code.

[0035] The traceability index module includes a database server and a query interface unit. The database server uses a relational database to store the bound traceability data, and the query interface unit supports retrieving all historical parameters of the output axis on the production line by inputting an identification code.

[0036] During operation, the cycle time coordination control unit monitors the material accumulation at each workstation in real time using the load calculation unit; if the processing load at a certain workstation deviates from the specified value... If the material level exceeds the preset threshold, the flow scheduling module determines that there is a risk of material accumulation at that workstation and immediately reduces the operating frequency of the conveyor drive device to slow down the material supply speed of the preceding workstation; if If the value is below the preset threshold, the workstation is determined to be in an idle or waiting state, and the flow scheduling module increases the operating frequency to speed up the material flow.

[0037] The precision compensation monitoring terminal maintains machining accuracy through a closed-loop feedback mechanism; after each batch of output shafts is machined, the 3D scanning module performs full-size inspection on randomly selected samples; the deviation calculation module compares the inspection data with the design specifications in real time; if the radial deviation value or straightness deviation... When a trend of drift is observed, the instruction feedback module immediately generates a reverse compensation instruction. This instruction is directly injected into the parameter storage area of ​​the CNC system, and the tool path is automatically adjusted in the next machining cycle to achieve adaptive correction of machining accuracy.

[0038] The wear early warning analysis terminal improves detection reliability through multi-sensor information fusion technology; the interference suppression module monitors the environmental vibration benchmark in real time through a decoupling algorithm; when the environmental vibration fluctuates drastically, the system automatically adjusts the weighting coefficients in the health assessment module. and This reduces reliance on vibration signals, increases the proportion of current signal monitoring, and prevents environmental interference from triggering false alarms.

[0039] The full-process traceability management terminal ensures the integrity of the data chain through a distributed storage structure. After the local controller of each process node completes the data acquisition, it first caches the data locally and adds a cyclic redundancy check code. When the network is idle, it uploads the data to the central database server. If a communication interruption occurs during the upload process, the system will automatically resume the transmission after the communication is restored, ensuring that the processing parameters of each output shaft can be accurately traced back.

[0040] In the overall system operation process, the central control matrix acts as the core node, coordinating the logical interactions between various terminals. When the accuracy compensation monitoring terminal detects that multiple consecutive samples show dimensional deviations in the same direction, the central control matrix, in conjunction with the wear warning analysis terminal, retrieves the equipment health index for that period. ;like During synchronous descent, the system determines the deviation is caused by tool wear and automatically triggers a tool replacement reminder; if If the settings remain normal, it is determined that there is a deviation in the process parameter settings, and the system will automatically execute parameter optimization logic.

[0041] The present invention has the following beneficial effects:

[0042] 1. In this invention, by setting up a cycle time coordination control terminal, the material sensing array and load calculation unit are used to obtain the processing load deviation of each station in real time during the production process of the power tool output shaft, and the operating frequency of the conveying drive device is dynamically adjusted accordingly. This specific technical means solves the problem that material accumulation or idling is easy to occur at some stations of the production line in the prior art, eliminates the delay phenomenon of cycle time adjustment, and significantly improves the overall flow efficiency and operation continuity of the line.

[0043] 2. In this invention, by setting up a precision compensation monitoring terminal, the spatial coordinate point set of the output axis is obtained using a 3D scanning module, and the radial deviation and axis straightness deviation are calculated in real time using a deviation calculation module. By vectorizing the deviation and directly converting it into compensation commands for the CNC system, real-time feedback and adaptive compensation of machining accuracy are achieved. Compared with the traditional manual sampling and manual machine adjustment mode, this solution significantly improves the consistency of machining accuracy and reduces the defect rate through a closed-loop control link.

[0044] 3. In this invention, by setting up a wear early warning analysis terminal, a multi-parameter fusion monitoring scheme of vibration signal and current signal is adopted, and a signal decoupling algorithm in the interference suppression module is used. This method effectively eliminates the complex environmental vibration and electromagnetic interference in the production workshop, enabling the system to accurately extract the wear characteristic frequency of key components. Through the health index calculated by the health assessment module, the system can provide more scientific predictive maintenance suggestions than traditional timed maintenance, avoiding losses caused by unexpected equipment downtime.

[0045] 4. In this invention, by setting up a full-process traceability management terminal, a unique identification code etching and multi-process parameter automatic association technology are adopted; the system not only records the processing results, but also retains process parameters such as heat treatment temperature and feed rate completely through the timestamp association unit; this data construction method solves the problems of incomplete quality traceability data chain and limited identification methods in the prior art, and provides a complete and accurate data base for subsequent process optimization and root cause analysis of failures. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the overall system architecture of an intelligent management system for the output shaft production line of an electric tool according to the present invention;

[0047] Figure 2 This is a schematic diagram of the cycle time coordination control terminal of an intelligent management system for an output shaft production line of an electric tool according to the present invention;

[0048] Figure 3 This is a schematic diagram of the architecture of the precision compensation monitoring terminal of the intelligent management system for the output shaft production line of an electric tool according to the present invention.

[0049] Figure 4This is a schematic diagram of the wear early warning analysis terminal of an intelligent management system for an output shaft production line of an electric tool according to the present invention;

[0050] Figure 5 This is a schematic diagram of the full-process traceability management terminal of the intelligent management system for the output shaft production line of an electric tool according to the present invention. Detailed Implementation

[0051] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0052] Example 1, please refer to Figures 1 to 2 As shown: An intelligent management system for a power tool output shaft production line includes a cycle time coordination control terminal, a precision compensation monitoring terminal, a wear early warning analysis terminal, and a full-process traceability management terminal. The cycle time coordination control terminal, the precision compensation monitoring terminal, the wear early warning analysis terminal, and the full-process traceability management terminal communicate bidirectionally via an industrial Ethernet bus, and each terminal is electrically connected to a central control matrix.

[0053] The cycle time coordination control terminal is used to obtain the material distribution level signal of each station of the output shaft production line, combine it with the preset standard production time of the process, calculate the processing load deviation of each processing node in real time, and adjust the output frequency of the frequency converter to keep the speed of the conveyor motor dynamically synchronized with the current processing progress.

[0054] The precision compensation monitoring terminal is used to collect the surface geometric shape data of the output shaft after machining in a non-contact manner, convert the shape data into a three-dimensional spatial point set, and compare it with the pre-stored standard model to calculate the real-time deviation vector of the machining features. Then, the deviation vector is converted into tool compensation commands and fed back to the CNC machining unit to realize closed-loop correction of machining accuracy.

[0055] The wear warning analysis terminal is used to collect composite operating signals of the processing equipment through multi-dimensional sensors, use signal decoupling logic to remove environmental background noise, extract the wear characteristic frequency of key rotating parts, and calculate the equipment health index based on the amplitude drift of the characteristic frequency. When the health index is lower than the safety threshold, a maintenance warning is triggered.

[0056] The full-process traceability management terminal is used to etch a unique identification code on the non-working end face of the output shaft and automatically associate it with real-time processing parameters, environmental monitoring data and test results at each process node to build a structured quality traceability database, thus completing the closed loop of the full life cycle data chain of the output shaft from raw material feeding to finished product warehousing.

[0057] The cycle time coordination control terminal includes a workstation load monitoring module, a flow scheduling module, and a drive control module.

[0058] The workstation load monitoring module includes a sensing unit, a timing unit, and a load calculation unit. The sensing unit is used to acquire the pulse signals of the output shaft entering and leaving the workstation by using infrared photoelectric sensors that are set in pairs at the entrance and exit of each processing workstation. The timing unit is used to record the time difference between two adjacent pulse signals as the actual processing time of the output shaft at the current workstation.

[0059] The load calculation unit is used to calculate the processing load deviation based on the actual processing time and the preset standard time. The specific calculation formula is as follows:

[0060] ;

[0061] in, Indicates the deviation of processing load. Indicates the first The actual processing time for each workstation. Indicates the first The preset standard processing time for each workstation. This indicates the total number of workstations.

[0062] The flow scheduling module includes a rate calculation unit and a flow instruction unit; the rate calculation unit is used to calculate the processing load deviation. The numerical value is used to dynamically calculate the target linear speed of the conveyor belt; the flow instruction unit is used to convert the target linear speed into a pulse width modulation (PWM) signal and transmit it to the drive control module.

[0063] The drive control module includes a frequency converter and a conveyor motor. The frequency converter is electrically connected to the conveyor motor and changes the speed of the conveyor motor by adjusting the output voltage frequency, thereby eliminating the accumulation of materials or idling between workstations.

[0064] Example 2, please refer to Figure 3 As shown: Based on Embodiment 1, the accuracy compensation monitoring terminal includes a three-dimensional scanning module, a deviation calculation module, and a command feedback module;

[0065] The newly constructed 3D scanning module includes a laser emission unit, an image acquisition unit, and a coordinate construction unit.

[0066] The laser emitting unit is used to project line-scan structured light onto the output shaft surface, the image acquisition unit is used to acquire structured light images modulated by the output shaft topography, and the coordinate construction unit uses the triangulation principle to construct a three-dimensional coordinate point set on the output shaft surface.

[0067] The deviation calculation module is used to calculate the deviation between the actual geometric dimensions of the output shaft and the design standard. The specific steps are as follows:

[0068] Step 1: Set the central axis of the standard model as the reference axis, establish a three-dimensional rectangular coordinate system, and perform spatial alignment and normalization on the collected three-dimensional coordinate point set;

[0069] Step 2: Fit the center coordinates of the key section of the output shaft using the least squares method, calculate the difference between the actual radius and the standard radius, and obtain the radial deviation value;

[0070] Step 3: Calculate the straightness deviation of the output shaft axis. The calculation formula is as follows:

[0071] ;

[0072] in and They represent the first The center point of each section relative to the reference axis is shaft and Offset in the axial direction Indicates the number of cross-sectional samples.

[0073] The instruction feedback module includes a deviation vectorization unit and a compensation instruction generation unit;

[0074] The deviation vectorization unit is used to synthesize the radial deviation value and the straightness deviation $f$ into a spatial deviation vector;

[0075] The compensation instruction generation unit is used to calculate the tool compensation increment of the CNC machine tool based on the spatial deviation vector, and encapsulate the increment into a data packet and send it to the actuator of the CNC system.

[0076] Example 3, please refer to Figure 4 As shown: Based on Embodiment 1, the wear warning analysis terminal includes a signal acquisition module, an interference suppression module, and a health assessment module.

[0077] The signal acquisition module includes an accelerometer and a current transformer. The accelerometer is installed in the bearing housing of the grinding machine spindle and is used to acquire high-frequency vibration signals. The current transformer is coupled to the power supply cable of the spindle motor and is used to acquire spindle current fluctuation signals.

[0078] The interference suppression module includes a filtering unit and a decoupling unit; the filtering unit is used to filter out mechanical background noise outside the preset frequency range using a bandpass filter; the decoupling unit is used to separate the inherent vibration signal of the equipment from the external environmental interference signal in the vibration signal through an independent component analysis algorithm to ensure the purity of wear feature extraction.

[0079] The health assessment module is used to assess the physical condition of the equipment through real-time monitoring data. The specific calculation process is as follows:

[0080] Step 1: Calculate the coefficient of the linear term of the health assessment indicators, using the following formula:

[0081] ;

[0082] in, The coefficient of the first term represents the degree of linear correlation between the change in vibration amplitude and the current fluctuation. For the first The real-time vibration amplitude collected in this second sampling. This is the reference vibration amplitude under standard conditions. For the first The real-time current value collected this time. The reference current value, This represents the number of samples collected.

[0083] Step 2: Calculate the quadratic coefficients of the health assessment indicators, using the following formula:

[0084]

[0085] in, The coefficient of the quadratic term reflects the nonlinear evolution trend of current fluctuations under large amplitude conditions.

[0086] Step 3: Construct a calculation model for the equipment health index $H$ based on the coefficients of the linear and quadratic terms:

[0087] ;

[0088] in, Indicates the equipment health index. and The weighting coefficients are preset, and the weighting is dynamically adjusted by the central control matrix according to the environmental vibration intensity. If the calculated health index $H$ is lower than the preset safety threshold, the system will immediately trigger a maintenance warning signal and send it to the manual processing terminal.

[0089] Example 4, please refer to Figure 5 As shown: Based on Embodiment 1, the full-process traceability management terminal includes an identification code etching module, a process association module, and a traceability index module.

[0090] The identification code etching module includes a laser etching machine and a visual verification unit. The laser etching machine generates a QR code containing batch information on the output shaft end face, and the visual verification unit is used to confirm the uniqueness and reading accuracy of the QR code.

[0091] The newly established process association module includes a data acquisition gateway and a timestamp association unit. The data acquisition gateway acquires the heat treatment furnace temperature, fine grinding feed speed and ambient humidity in real time through the fieldbus. The timestamp association unit binds the above process parameters with the QR code recognition code in a time sequence.

[0092] The traceability index module includes a database server and a query interface unit. The database server uses a distributed storage architecture to store the bound traceability data, and the query interface unit supports retrieving the full process file of the output shaft by inputting an identification code.

[0093] In this invention, an intelligent management system for a power tool output shaft production line first sets the standard processing time for each workstation via a cycle time coordination control terminal during system operation. The load calculation unit monitors the material flow status of each processing node in real time; if the processing load of a certain station deviates from the specified value... If the threshold is exceeded, it is determined that there is a risk of material backlog at the node. The flow scheduling module then reduces the operating frequency of the preceding conveyor device, and vice versa, thereby eliminating the production bottleneck caused by local accumulation and ensuring the continuity of the entire line operation.

[0094] Subsequently, during the machining cycle, the precision compensation monitoring terminal uses a 3D scanning module to perform real-time spot checks on the output shaft; the deviation calculation module compares the collected point cloud data with the standard model to calculate the straightness deviation of the axis. Once a trend of deviation is detected, the compensation command generated by the instruction feedback module will directly correct the feed parameters of the CNC system, realizing adaptive accuracy repair in the next cycle and solving the problem of machining accuracy feedback compensation delay.

[0095] Meanwhile, the wear early warning analysis unit works in conjunction with an accelerometer and a current transformer; the interference suppression module uses a decoupling algorithm to eliminate interference from workshop environmental vibrations on the signal; and the health assessment module calculates the health index in real time based on the characteristic frequency amplitude. When fatigue wear occurs in the spindle bearing, leading to... When the value decreases, the system automatically switches the monitoring weight to enhance the capture of abnormal current frequencies, prevent environmental interference from triggering false alarms, and ensure the accuracy of equipment maintenance early warning.

[0096] Finally, the end-to-end traceability management system completes the etching of identification codes during the raw material loading stage. In subsequent heat treatment, rough machining, and fine grinding processes, the data acquisition gateway forcibly associates process parameters with the timestamps of the identification codes. All data is uploaded to the database server after cyclic redundancy verification. If quality fluctuations are subsequently detected, managers can retrieve all historical processing parameters of the output shafts of that batch through the query interface, thus realizing a complete closed loop of the quality traceability data chain and providing data support for process improvement.

[0097] To enable those skilled in the art to fully understand and implement this invention, the specific implementation principles of this invention are further supplemented below with a specific application scenario.

[0098] In the automated production process of high-torque output shafts for power tools, after the system starts, the full-process traceability management terminal intervenes first. The blank part is placed on the fixture at the marking station by the feeding robot. The laser etching machine in the identification code etching module receives the start command from the central control matrix and uses a high-energy laser beam to etch a QR code containing the production date, batch number, and unique serial number on the non-working end face of the output shaft, that is, the flat end face that does not contact the gears or bearings. Immediately afterwards, the industrial camera in the vision verification unit captures the etched QR code instantly. The image comparison logic confirms whether the edge clarity and contrast of the QR code meet the reading standard. If the verification is successful, the identity information of the output shaft is activated in the database server, laying the physical foundation for subsequent process data association.

[0099] Upon entering the roughing stage, the cycle time coordination control unit begins to play its role in precisely scheduling the production cycle time. The output shaft moves with the conveyor belt; when it passes the entrance of the roughing station, the infrared photoelectric sensor is blocked, generating a high-level transition signal, and the timing unit immediately starts timing. After the output shaft completes the finishing process on the CNC lathe and exits, it generates another pulse signal when it passes the infrared photoelectric sensor at the exit, causing the timing unit to stop timing and output the actual processing time. After the load calculation unit obtains this duration, it compares it with the standard process duration stored in the central control matrix. A comparison is performed; in actual operation, if the cutting speed decreases due to uneven hardness of the workpiece, resulting in the actual time of multiple stations being greater than the standard time, the load calculation unit calculates the machining load deviation according to the formula. It will show an upward trend; at this time, the rate calculation unit in the flow scheduling module senses... The change in value calculates the incremental reduction in conveying speed required, and the flow instruction unit generates an adjusted pulse width modulation signal. After receiving the signal, the frequency converter in the drive control module reduces the frequency of the output current, so that the speed of the conveying motor decreases smoothly, thereby slowing down the frequency of subsequent blanks entering the station. This frequency adjustment mechanism based on real-time processing feedback avoids the accumulation of materials in front of inefficient stations from a physical perspective, ensuring the momentum balance between nodes of the production line.

[0100] When the output shaft enters the inspection stage before the fine grinding station, the precision compensation monitoring terminal performs geometric morphology calibration on the semi-finished product through non-contact measurement. The laser emission unit in the 3D scanning module projects linear structured light onto the surface of the high-speed rotating output shaft, while the image acquisition unit captures the structured light stripes modulated by the undulations of the output shaft surface at a high frame rate. The coordinate construction unit uses trigonometric relationships to convert the pixel coordinates in the image into a set of spatial 3D coordinate points. The deviation calculation module then intervenes, using a preset standard axis centerline as a reference to spatially align the acquired point cloud. The least squares method is used to fit the circumferential points of different cross sections to determine the actual center point position of each cross section. At this point, the system calculates the straightness deviation based on the formula for the axis. Value; if If the value exceeds the micron-level tolerance allowed by the process, the deviation vectorization unit will determine the specific azimuth angle and modulus of the deviation; the compensation instruction generation unit will convert this vector information into the offset parameters of the CNC system and inject it into the control kernel of the precision grinding machine in real time through the industrial Ethernet bus; after receiving the instruction, the actuator of the precision grinding machine will automatically fine-tune the grinding wheel feed compensation amount. This real-time physical parameter correction ensures that the machining error of each output shaft can be compensated in the next process, effectively solving the problem of dimensional drift caused by machine tool thermal deformation or tool wear.

[0101] During the fine grinding operation, the wear early warning analysis terminal monitors the health status of the machining spindle around the clock; the accelerometer installed on the spindle bearing housing senses the vibration waveform generated by the spindle rotation, while the current transformer coupled to the motor cable captures minute fluctuations in current; the filtering unit in the interference suppression module first eliminates low-frequency vibration noise generated by other heavy equipment in the workshop; the decoupling unit then separates the natural frequency of the spindle rotation from the high-frequency impact characteristic frequency caused by pitting of the bearing balls through logical operations; and the health assessment module acquires the real-time vibration amplitude. With real-time current value Under normal processing conditions, vibration and current remain at reference values. and Nearby, health index At a high level; as machining time progresses, if fatigue spalling occurs in the spindle bearing, the vibration amplitude will be the first to experience an abnormal jump, leading to an increase in the coefficient of the first term. With the coefficient of the quadratic term The value has shifted; the central control matrix dynamically adjusts the value based on the current environmental vibration intensity. The weights are used to verify the authenticity of the vibration signal by assessing the stability of the current signal; when the final calculated... When the index continuously falls below the safety threshold, the system immediately sends a maintenance warning to the manual terminal and coordinates with the cycle time control terminal to reduce the feeding speed of that station until manual intervention is completed. This preventive maintenance mechanism greatly reduces downtime losses caused by unplanned shutdowns of the production line.

[0102] Throughout the entire processing lifecycle, the end-to-end traceability management system records all critical data. Whenever the output shaft passes through a heat treatment furnace, grinding mill, or testing station, the data acquisition gateway captures the current process environment parameters in real time via fieldbus. For example, during the heat treatment stage, the timestamp association unit precisely binds the real-time temperature curve, quenching oil temperature, and ambient humidity within the heat treatment furnace to the unique identification code of the output shaft. This data, after undergoing cyclic redundancy verification, is then distributed and stored by the database server. During the final inspection before finished product warehousing, if the surface hardness of a batch of output shafts is found to be substandard, quality inspectors only need to scan the QR code on the output shaft end face using the query interface unit. The system can then instantly retrieve all processing details the product underwent in the past few hours, including the load deviation at that time. Straightness deviation and equipment health index By tracing back the data, managers can clearly identify that the quality defects were caused by temperature fluctuations in the heat treatment furnace during a specific period, thus providing precise physical evidence for optimizing the process.

[0103] All content not described in detail in the specification belongs to the prior art known to those skilled in the art, and the communication protocols and sensor parameters of each module are not specifically limited. Conventional industrial-grade equipment can be used. The underlying circuit control components not mentioned in this technical solution are prior art and will not be described here.

[0104] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. An intelligent management system for a power tool output shaft production line, characterized in that, It includes a cycle time coordination control terminal, a precision compensation monitoring terminal, a wear early warning analysis terminal, and a full-process traceability management terminal. The cycle time coordination control terminal, the precision compensation monitoring terminal, the wear early warning analysis terminal, and the full-process traceability management terminal communicate bidirectionally via an industrial Ethernet bus, and each terminal is electrically connected to the central control matrix. The cycle time coordination control terminal includes a workstation load monitoring module, a flow scheduling module, and a drive control module. The workstation load monitoring module acquires real-time material distribution data of each workstation on the output shaft production line through a material sensing array, and calculates the processing load deviation of each processing node in combination with the standard process duration. The flow scheduling module adjusts the operating frequency of the drive control module according to the processing load deviation. The workstation load monitoring module includes a sensing unit, a timing unit, and a load calculation unit. The sensing unit acquires the entry and exit level signals of the output shaft through infrared through-beam sensors symmetrically arranged at the entrance and exit of each processing workstation. The timing unit records the time interval between two adjacent entry and exit level signals as the actual processing time.

2. The system according to claim 1, characterized in that, The load calculation unit calculates the load based on the actual processing time. With preset standard processing time Calculate the deviation of the processing load The calculation formula is as follows: ； in, This indicates the total number of workstations.

3. The system according to claim 2, characterized in that, The precision compensation monitoring terminal includes a three-dimensional scanning module, a deviation calculation module, and an instruction feedback module. The three-dimensional scanning module acquires the geometric features of the output shaft after processing through laser scanning and converts them into a set of spatial coordinate points. The deviation calculation module is used to compare the set of spatial coordinate points with a standard model to calculate the real-time deviation vector of the processing parameters. The instruction feedback module is used to convert the deviation vector into compensation instructions and feed them back to the CNC machining unit.

4. The system according to claim 3, characterized in that, The deviation calculation module performs axis straightness deviation calculation. The calculation formula is as follows: ； in and They represent the first The center point of each section relative to the reference axis is shaft and Offset in the axial direction Indicates the number of cross-sectional samples.

5. The system according to claim 1, characterized in that, The wear warning analysis terminal includes a signal acquisition module, an interference suppression module, and a health assessment module; the signal acquisition module includes an accelerometer for acquiring spindle vibration signals and a current transformer for acquiring spindle current signals; the interference suppression module uses a signal decoupling algorithm to eliminate environmental vibration and electromagnetic interference.

6. The system according to claim 5, characterized in that, The interference suppression module includes a filtering unit and a decoupling unit; the filtering unit uses a bandpass filter to filter out environmental noise outside a preset frequency range; the decoupling unit uses an independent component analysis algorithm to separate the inherent vibration signal of the equipment from the environmental interference signal in the vibration signal.

7. The system according to claim 5, characterized in that, The health assessment module calculates the device's health index. First, calculate the coefficient of the first term. and quadratic coefficient The calculation formulas are as follows: ； ； in, For the first The real-time vibration amplitude collected in this second sampling. This is the reference vibration amplitude under standard conditions. For the first The real-time current value collected this time. The reference current value, This represents the number of samples collected.

8. The system according to claim 7, characterized in that, The health assessment module calculates the equipment health index based on the amplitude changes of wear characteristic frequencies. The calculation formula is as follows: ； in, This represents the vibration amplitude collected in real time. This represents the real-time collected motor current value. The central control matrix represents the preset weighting coefficients and is dynamically adjusted according to the environmental vibration intensity. and The value.

9. The system according to claim 1, characterized in that, The full-process traceability management terminal includes an identification code etching module, a process association module, and a traceability index module. The identification code etching module is used to etch a unique identification code on the end of the output shaft. The process association module is used to automatically associate processing parameters, environmental parameters, and test data at each processing process node. The traceability index module is used to construct a multi-dimensional quality traceability database.

10. The system according to claim 1, characterized in that, The central control matrix is ​​configured with linkage processing logic. When the accuracy compensation monitoring terminal detects that multiple consecutive samples have size deviations in the same direction and the wear warning analysis terminal calculates the equipment health index, the logic will be activated. During synchronous descent, the central control matrix determines that the deviation is caused by tool wear and triggers a tool replacement reminder. When the device health index When operating normally, the central control matrix determines that there is a deviation in the process parameter settings and executes parameter optimization logic.

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