Intelligent prediction method for wear state of stamping die

Abstract

The application discloses an intelligent prediction method for the wear state of a stamping die, and relates to the technical field of intelligent manufacturing. The method comprises the following steps: collecting multi-point stamping force data, slider phase data, material belt feeding data, work station arrangement data and work station failure boundary data of continuous punching times, and generating material belt unit transfer data based on the material belt feeding data and the work station arrangement data; registering the multi-point stamping force data and the slider phase data to obtain phase stamping force data, splitting the stamping force values superimposed in the same punching time according to the phase stamping force data and the work station arrangement data, and generating work station load components; generating the transfer state values between adjacent work stations and the residence state values in the same work station according to the material belt unit transfer data and the work station load components; and the application can distinguish the work station load superposition in the same punching time from the secondary abnormality along the material belt transmission, and improve the accuracy of the wear source work station identification and the remaining available punching time prediction of each work station.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, specifically to an intelligent prediction method for the wear state of stamping dies. Background Technology

[0002] The wear condition prediction of stamping dies is mainly aimed at the continuous production process of multi-station progressive dies. It usually judges the service condition of die cutting edges, inserts or forming parts by press force information, slide movement information, feeding information and station layout. It can provide a reference for grinding, replacement and production cycle adjustment, so that die maintenance can gradually shift from periodic inspection to process monitoring and condition judgment.

[0003] Currently, in the continuous stamping process of multi-station progressive dies, multiple stations complete punching, trimming, bending or shaping actions in the same stroke. The stamping force response collected by the press is often generated by the superposition of multiple stations. If the wear state is judged only based on the peak value of the total stamping force or the change of a single force measuring position, it is easy to mix the force changes of multiple stations into the same judgment result, making it difficult to distinguish the station where wear has occurred.

[0004] Secondly, wear at upstream stations can alter the position of the strip holes, the edge profile, or the state of local deformation. When the altered strip continues to enter downstream stations, it can cause abnormal punching pressure at the downstream stations. This abnormality does not necessarily originate from the wear at the downstream stations themselves. If the effects of the original wear and the secondary abnormalities after transmission cannot be distinguished, it can easily lead to misjudgment of the wear source station and affect the accuracy of the prediction of the remaining available punches at each station. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention provides an intelligent prediction method for the wear state of stamping dies, the method comprising:

[0006] Collect multi-point punching force data, slider phase data, strip feeding data, station layout data and station failure boundary data of continuous punches, and generate strip unit transfer data based on strip feeding data and station layout data;

[0007] Based on multi-point punching force data and slider phase data, phase punching force data is obtained by registration. The superimposed punching force value within the same punching cycle is split according to the phase punching force data and station layout data to generate station load components.

[0008] Based on the data transmitted by the conveyor belt unit and the load components of the workstation, the transfer status value between adjacent workstations and the dwell status value within the same workstation are generated. The workstation load attribution data is then generated using the transfer status value and the dwell status value.

[0009] The wear source station is determined based on the workstation load attribution data, and the corresponding workstation load component of the downstream workstation is corrected through the wear source station to generate the wear state value of each workstation. Based on the wear state value of each workstation and the workstation failure boundary data, the remaining available strokes of each workstation are generated.

[0010] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0011] This invention transmits data, phase punching force data, and station load components through the material strip unit, enabling the superimposed punching force values ​​within the same punch in a multi-station progressive die to be decomposed according to the station number, reducing station load confusion caused by the overlapping of punching force responses from multiple stations, and thereby improving the accuracy of the correspondence between station load components and actual force-bearing stations.

[0012] Furthermore, this invention also distinguishes between the load value transferred by the conveyor belt that enters the downstream station number along with the conveyor belt unit number and the load value of the station itself that is fixed under the same station number by using the transfer state value, the residence state value and the station load attribution data. The transfer load part in the downstream station number is deducted from the station load component to obtain the wear state value of each station that is closer to the actual wear of each station, thereby improving the accuracy of wear source station identification and prediction of the remaining available strokes of each station.

[0013] In summary, this invention can distinguish between the superposition of loads at the same workstation and the secondary anomalies transmitted along the material belt within the same stroke, thereby improving the accuracy of identifying wear source workstations and predicting the remaining available strokes at each workstation. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0015] Figure 1 A flowchart of an intelligent prediction method for the wear state of a stamping die provided by the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Please see Figure 1As shown in the figure, this embodiment discloses an intelligent prediction method for the wear state of stamping dies, the method comprising:

[0018] S11: Collect multi-point punching force data, slider phase data, material strip feeding data, station layout data and station failure boundary data of continuous punches, and generate material strip unit transmission data based on material strip feeding data and station layout data;

[0019] In one specific embodiment, multi-point punching force data is synchronously acquired by multiple force sensors installed on the press bed, slide, or die holder; slide phase data is acquired by the press crankshaft encoder or slide position encoder; strip feeding data is acquired by the servo feed controller or strip position detection device; station layout data is obtained by reading progressive die design documents or die control system; and station failure boundary data is determined by die trial data, historical maintenance data, or process setting data.

[0020] Specifically, the multi-point punching force data includes punch number, force measurement position number, force measurement position coordinates, sampling time, and punching force value; the slider phase data includes punch number, sampling time, slider phase value, upper dead point mark, and lower dead point mark; the material feeding data includes punch number, feeding step distance value, material strip front end position value, and material strip unit length value; the station layout data includes station number, station sequence number, station center coordinates, and station action length value; and the station failure boundary data includes station number and station failure load value.

[0021] In one specific embodiment, a series of strokes refers to multiple stamping cycles completed by the press according to the stamping cycle, and the stroke number is represented as follows: The force measurement location number is represented as The workstation number is represented as The material strip unit number is represented as The sampling time is represented as .

[0022] The punching force value in the multi-point punching force data is expressed as:

[0023]

[0024] in, Indicates the stroke number is The force measurement location is numbered as follows Sampling time is The impact force value collected at that time.

[0025] The slider phase value is represented as:

[0026]

[0027] in, Indicates the stroke number is Sampling time is The corresponding slider phase value.

[0028] The position value of the front end of the material strip is expressed as ,in, Indicates the stroke number is The position value of the front end of the conveyor belt in the feeding direction, and the feeding step value are expressed as follows: ,in, Indicates the stroke number is The corresponding feeding step distance value and the strip unit length value are expressed as follows: ,in, This indicates the length value used when dividing the strip into sections. The strip unit length value is determined by the progressive die feed step distance, the shortest station action length, or the distance between adjacent positioning holes on the strip.

[0029] The coordinates of the workstation center are represented as ,in, Indicates the workstation number is The coordinates of the workstation center are obtained, and the position components of the workstation center coordinates are extracted along the feeding direction and represented as follows: The working length value of the workstation is expressed as ,in, Indicates the workstation number is The length of the material strip subjected to stamping in the feeding direction is represented by the station failure load value. ,in, Indicates the workstation number is The corresponding workstation failure load value.

[0030] Specifically, the steps for generating the data transmission unit are as follows:

[0031] S111: Based on the position value of the front end of the strip and the length value of the strip unit, divide the strip position segment within the continuous strokes and generate the strip unit number;

[0032] In one specific embodiment, the feeding direction is used as a one-dimensional position axis, and the strokes are numbered as follows: The position value of the front end of the conveyor belt at that time As the starting point reference for the material strip position section, and according to the material strip unit length value Divide the material strip into equal intervals.

[0033] The material strip position segment corresponding to the material strip unit number is represented as follows:

[0034]

[0035] in, Indicates the stroke number is The material strip unit number is The corresponding material strip location section, It is an integer number that increases sequentially from the front end of the conveyor belt in the opposite direction of feeding.

[0036] It should be noted that the material strip unit number is generated according to the arrangement order of the material strip position segments. The same material strip unit number moves with the material strip feeding action between adjacent strokes, so that the movement process of the same material strip segment between different workstation numbers can be tracked later.

[0037] S112: Calculate the material belt movement distance between adjacent strokes by using the feeding step distance value and the material belt front end position value to obtain the stroke feeding distance value;

[0038] In one specific embodiment, the stroke number is read as The position value of the front end of the conveyor belt at that time And read the stroke number as The position value of the front end of the conveyor belt at that time Calculate the position difference of the front end of the conveyor belt in the feeding direction between adjacent strokes.

[0039] The feed distance per stroke is expressed as:

[0040]

[0041] in, Indicates the stroke number is The corresponding feed distance value per stroke.

[0042] When the servo feed controller outputs the feed step value The feed distance per stroke calculated from the position value of the front end of the conveyor belt When there is a discrepancy, the feed distance per stroke calculated using the position value of the front end of the conveyor belt shall be used. It participates in the generation of data for subsequent material conveyor units.

[0043] It should be noted that using the position value of the front end of the conveyor belt to calculate the feeding distance per stroke can reflect the actual feeding distance after feeding slippage, conveyor belt rebound, or correction by the positioning pin.

[0044] S113: Based on the center coordinates of the workstation and the working length value, determine the material strip coverage area corresponding to each workstation number and generate the workstation coverage area;

[0045] In one specific embodiment, the coordinates of the workstation center are read along the feeding direction. Positional components in And read the workstation number as Corresponding workstation working length value The position component of the workstation center coordinates in the feeding direction is used as the interval center, and the workstation action length value is used as the interval length to determine the workstation coverage interval corresponding to the workstation number.

[0046] The workstation coverage area is represented as follows:

[0047]

[0048] in, Indicates the workstation number is The corresponding workstation coverage area.

[0049] It should be noted that: the station coverage area refers to the spatial range in which the station number performs punching, forming or shaping on the material strip in the feeding direction. The station coverage area is not the same as the entire mold installation range.

[0050] S114: Based on the material strip unit number, the feed distance value per stroke, and the station coverage area, write the station number corresponding to the material strip unit number for each stroke to generate material strip unit transfer data.

[0051] In one specific embodiment, the stroke number is read as The section of the material belt at that time Read the workstation number as Corresponding workstation coverage area Calculate the coverage length between the material strip location section and the workstation coverage area.

[0052] The coverage length value is represented as:

[0053]

[0054] in, Indicates the stroke number is The material strip unit number is Workstation number is At that time, the coverage length value between the material strip location section and the workstation coverage area. This represents the function for calculating the length of an interval.

[0055] When the coverage length value When the value is greater than zero, the stroke number will be assigned. Material strip unit number Workstation Number and coverage length value Data is transmitted by writing to the tape unit.

[0056] The data transmitted by the conveyor belt unit is represented as follows:

[0057]

[0058] in, This indicates that the conveyor belt unit transmits data.

[0059] It should be noted that the data transmitted by the conveyor belt unit retains the corresponding station number under different stroke numbers for the same conveyor belt unit number. This allows for subsequent determination of whether the load change caused by wear at the upstream station has entered the downstream station number based on the data transmitted by the conveyor belt unit.

[0060] S12: Based on multi-point punching force data and slider phase data, register to obtain phase punching force data, and split the superimposed punching force value within the same punch according to the phase punching force data and station layout data to generate station load components.

[0061] In one specific embodiment, a multi-station progressive die completes at least two stamping actions, such as punching, trimming, bending, drawing, or shaping, in the same stroke. The stamping force values ​​generated by different station numbers are transmitted to multiple force measuring position numbers through the press structure. Therefore, the stamping force value corresponding to each force measuring position number in the multi-point stamping force data is the result of the load superposition of multiple station numbers.

[0062] Specifically, the steps for generating workstation load components are as follows:

[0063] S121: Based on the stroke number and sampling time, match the stroke force value with the slider phase value to generate force phase pairing data;

[0064] In one specific embodiment, the impact number, force measurement position number, sampling time and impact force value are read from the multi-point impact force data, and the impact number, sampling time and slider phase value are read from the slider phase data.

[0065] For the same stroke number At the same sampling time Corresponding impact force value and slider phase value Write the same pairing content to generate force measurement phase pairing data.

[0066] Force phase pairing data is represented as follows:

[0067]

[0068] in, This indicates the force measurement phase pairing data.

[0069] When the sampling times of the punch force value and the slider phase value are inconsistent, the sampling time corresponding to the punch force value is used as the reference, and the slider phase data at the sampling time is read. The two sampling times before and after are denoted as follows: and And perform linear interpolation on the slider phase value.

[0070] The interpolated slider phase value is expressed as:

[0071]

[0072] in, and For the slider phase data located at the sampling time Sampling times on both sides Indicates the sampling time The corresponding slider phase value, Indicates the sampling time The corresponding slider phase value.

[0073] S122: By using the force measurement phase pairing data, the upper dead point mark, and the lower dead point mark, the impact force value under each force measurement position number is corrected, and phase impact force data is generated;

[0074] Specifically, the steps for generating phase impulse data are as follows:

[0075] S122.1: Based on the force phase pairing data, read the impulse force value corresponding to each sampling time under the same impulse number to obtain the impulse force value of the impulse;

[0076] In one specific embodiment, for the stroke numbered The force measurement phase pairing data is arranged according to the force measurement position number. Read the impulse force value corresponding to each sampling time.

[0077] The punching force value is expressed as:

[0078]

[0079] in, Indicates the stroke number is The force measurement location is numbered as follows The corresponding punching force value, Indicates the stroke number is The number of samples corresponding to the time.

[0080] S122.2: By using the top dead center mark and the bottom dead center mark, calibrate the slider phase value corresponding to the punch force value to obtain the standard slider phase value;

[0081] In one specific embodiment, the sampling time corresponding to the upper stop point marker is denoted as... The sampling time corresponding to the lower endpoint marker is recorded as... The slider running interval between the top dead center mark and the bottom dead center mark is taken as the suppression phase interval, and the slider phase value within the suppression phase interval is normalized to obtain the standard slider phase value.

[0082] The standard slider phase value is expressed as:

[0083]

[0084] in, Indicates the stroke number is Sampling time is The corresponding standard slider phase value, Indicates the stroke number is The sampling time corresponding to the upper and middle stop points is marked. Indicates the stroke number is The sampling time corresponding to the middle and lower stop points.

[0085] It should be noted that the standard slider phase value is the normalized slider phase value, and the range of the standard slider phase value is [range missing]. Where 0 corresponds to the top dead center mark and 1 corresponds to the bottom dead center mark; for example, when lie in and When it is in the middle position, the standard slider phase value is 0.5.

[0086] S122.3: Based on the standard slider phase value and force measurement position number, rearrange the values ​​of the punching force under different force measurement position numbers to generate phase punching force data;

[0087] In one specific embodiment, a standard phase sampling point is set. ,in, Indicates the standard phase sampling point number. , Indicates the number of standard phase sampling points; standard phase sampling points are arranged according to... The range is set at equal intervals, and the number of standard phase sampling points is determined according to the sampling frequency of the press and the stamping cycle.

[0088] For stroke number Force measurement location number and standard phase sampling point number Read the standard phase sampling point The phase values ​​of two adjacent standard sliders are respectively represented as and And read the corresponding impact force value. and The phase impulse value is generated by linear interpolation.

[0089] The phase impulse value is expressed as:

[0090]

[0091] in, Indicates the stroke number is The force measurement location is numbered as follows The standard phase sampling points are numbered as follows: The corresponding phase impulse value.

[0092] The phase impulse force value is written according to the impulse number, force measurement position number and standard phase sampling point number to generate phase impulse force data.

[0093] Phase impulse data is expressed as follows:

[0094]

[0095] in, This represents the phase impulse data.

[0096] S123: Based on the center coordinates of the workstation and the working length value of the workstation, filter the workstation numbers that participate in the stamping contact under the same slider phase value to obtain the participating workstation numbers;

[0097] In one specific embodiment, the workstation coverage area is read. And read the stroke number from the data transmitted by the conveyor belt unit. Corresponding material strip unit number and station number; stroke number The material strip unit number falls into the workstation number The corresponding workstation coverage area, and the standard phase sampling point number. When the phase impulse value corresponding to at least one of the next force measurement position numbers is not zero, the position number will be... As the workstation number involved.

[0098] The workstation number is represented as follows:

[0099]

[0100] in, Indicates the stroke number is The standard phase sampling points are numbered as follows: The corresponding workstation number at that time. This indicates the coverage length between the material strip location section and the workstation coverage area.

[0101] It should be noted that the participating workstation numbers are not directly set according to a fixed number of workstations, but are selected based on the material strip unit transmission data and phase punching force data, so that the workstation numbers that have not been in contact with the material strip unit number are not involved in the splitting of the superimposed punching force value within the same punching cycle.

[0102] S124: Based on the phase impact force data and the participating workstation number, split the superimposed impact force values ​​within the same stroke to generate the workstation load component.

[0103] In one specific embodiment, regarding the stroke number and standard phase sampling point number The resultant phase force value is calculated based on the phase impulse value corresponding to different force measurement position numbers.

[0104] The resultant force value of the phase is expressed as:

[0105]

[0106] in, Indicates the stroke number is The standard phase sampling points are numbered as follows: The corresponding phase resultant force value.

[0107] The coordinates of the force measurement position are represented as follows: The coordinates of the workstation center are represented as Calculate the phase torque value based on the phase impulse value and the coordinates of the force measurement position.

[0108] The phase torque value is expressed as:

[0109]

[0110]

[0111] in, and Both represent phase torque values. and This represents the coordinate components in the force measurement position coordinate system.

[0112] Read the participating workstation number The coordinates of the workstation center corresponding to each workstation number are used to represent the workstation load components as follows: ,in, Indicates the stroke number is Workstation number is The standard phase sampling points are numbered as follows: The corresponding workstation load component at that time.

[0113] Based on the resultant phase force value, the phase torque value, and the participating workstation number, establish the balance calculation formula for the workstation load components:

[0114]

[0115]

[0116]

[0117] in, and This represents the coordinate components in the coordinate system of the workstation center.

[0118] When the number of participating workstations is greater than three, a load continuity constraint value is added between adjacent standard phase sampling points. The load continuity constraint value is expressed as:

[0119]

[0120] in, Indicates the stroke number is The standard phase sampling points are numbered as follows: The corresponding load continuity constraint value.

[0121] The phase resultant force value, phase torque value, and load continuity constraint value are used together as the solution constraints to obtain the load components of each participating workstation number.

[0122] The workstation load components are represented as follows:

[0123]

[0124] in, This indicates the load component at the workstation.

[0125] It should be noted that the load components at the workstation are determined by the phase impact force data, the coordinates of the force measurement position, the coordinates of the workstation center, and the number of the participating workstations. The impact force value is not distributed equally according to the number of workstations.

[0126] S13: Based on the data transmitted by the material belt unit and the load components of the workstation, generate the transfer status value between adjacent workstations and the dwell status value within the same workstation, and generate workstation load attribution data through the transfer status value and the dwell status value.

[0127] In one specific embodiment, the conveyor data represents the station numbers traversed by the same conveyor unit number in consecutive strokes, and the station load component represents the load value under the same stroke, the same station number, and the same standard phase sampling point number. By tracking the movement of the same conveyor unit number between upstream and downstream station numbers through the conveyor data, and aligning the corresponding station load components by stroke, the system distinguishes between the load portion that moves with the conveyor unit number and the load portion that remains fixed under the same station number.

[0128] Specifically, the steps for generating workstation load attribution data are as follows:

[0129] S131: Based on the data transmitted by the material strip unit and the load component of the workstation, read the corresponding workstation load component when the same material strip unit number passes through the adjacent workstation number to obtain the cross-workstation load component.

[0130] In one specific embodiment, data is transferred from the conveyor belt unit. Read the unit number of the same material strip The corresponding workstation number under different stroke numbers. If the strip unit number... In the stroke number The corresponding upstream workstation number and in the stroke number The corresponding downstream workstation number And the workstation sequence number satisfies the downstream workstation number. Upstream work station number Then, the corresponding workstation load component is read.

[0131] The upstream load component is represented as:

[0132]

[0133] in, Indicates the material strip unit number Located at the upstream work station number At that time, in the stroke number and standard phase sampling point number The corresponding workstation load component.

[0134] The downstream load component is represented as:

[0135]

[0136] in, Indicates the material strip unit number Downstream workstation number At that time, in the stroke number and standard phase sampling point number The corresponding workstation load component.

[0137] The upstream and downstream load components are written according to the material strip unit number, upstream station number, downstream station number and standard phase sampling point number to obtain the cross-station load component.

[0138] The cross-station load component is represented as follows:

[0139]

[0140] in, Indicates the material strip unit number Upstream workstation number Downstream workstation number and standard phase sampling point number The corresponding cross-station load components.

[0141] S132: Calculate the number of strokes from the upstream station number to the downstream station number of the same material strip unit number by using the feeding step distance value and the station sequence number, and obtain the feeding stroke difference value.

[0142] In one specific embodiment, the workstation sequence number is read, and the sequence difference between adjacent workstation numbers is recorded as... When the upstream workstation number and downstream workstation number When numbering adjacent workstations, .

[0143] The difference in feeding strokes is expressed as:

[0144]

[0145] in, This indicates that the unit number of the same material strip starts from the upstream station number. Downstream workstation number Required feed stroke difference, Indicates the upstream workstation number The position component of the workstation center coordinates in the feeding direction. Indicates the downstream workstation number The position component of the workstation center coordinates in the feeding direction. Indicates the stroke number is The corresponding feeding step distance value.

[0146] When the servo feed controller has a feed correction function, the feed distance value per stroke is used. Alternate feed step value It is used in the calculation of the feeding stroke difference. The feeding stroke difference is an integer value. If the calculation result is not an integer, the feeding stroke difference is determined according to the stroke number of the same material belt unit number that actually arrives at the downstream station number in the material belt unit transmission data of adjacent strokes.

[0147] S133: Based on the cross-station load component and the difference in feeding strokes, calculate the load difference between adjacent station numbers for the same material strip unit number, and generate the transition state value between adjacent stations.

[0148] Specifically, the steps for generating transition state values ​​between adjacent workstations are as follows:

[0149] S133.1: Based on the data transmitted by the material strip unit, read the upstream station number and downstream station number corresponding to the same material strip unit number to obtain the adjacent station number pair;

[0150] In one specific embodiment, the data transmitted by the feed tape unit is read. Same material strip unit number This corresponds to multiple workstation numbers, which are then arranged according to workstation sequence. If two adjacent workstation numbers are upstream workstation numbers... and downstream workstation number Then the upstream workstation number will be... and downstream workstation number Write the same pair of adjacent workstation numbers.

[0151] Adjacent workstation number pairs are represented as follows:

[0152]

[0153] in, Indicates the material strip unit number The corresponding adjacent workstation number pairs.

[0154] S133.2: By using the difference in feeding strokes, calibrate the stroke number corresponding to the load component of the next spanning station to the adjacent station number, and obtain the stroke-aligned load component.

[0155] Specifically, the steps to obtain the impulse alignment load components are as follows:

[0156] S133.2.1: Based on the adjacent workstation number pairs, read the upstream load component corresponding to the upstream workstation number and the downstream load component corresponding to the downstream workstation number to obtain the cross-workstation load pairing value;

[0157] In one specific embodiment, adjacent workstation number pairs are read. Upstream workstation number and downstream workstation number Read the corresponding upstream load component from the cross-station load component. and downstream load components .

[0158] The span load pairing value is expressed as:

[0159]

[0160] in, Indicates the material strip unit number Upstream workstation number Downstream workstation number and standard phase sampling point number The corresponding span load pairing value.

[0161] S133.2.2: By using the difference in feeding strokes, the stroke number corresponding to the upstream load component in the span load pairing value is shifted to obtain the shifted upstream load component;

[0162] In one specific embodiment, the upstream load component Corresponding stroke number Increase the difference in feeding strokes , and obtain the stroke number after translation.

[0163] The stroke number after translation is represented as follows:

[0164]

[0165] in, This indicates the stroke number after translation.

[0166] The upstream load component after translation is expressed as:

[0167]

[0168] in, This indicates the upstream load component after translation, corresponding to the translated stroke number, upstream station number, and standard phase sampling point number, after the upstream load component is translated according to the difference in feeding strokes.

[0169] S133.2.3: Based on the upstream and downstream load components after translation, select load values ​​with the same stroke number to obtain the stroke-aligned load components.

[0170] In one specific embodiment, the upstream load component after translation is read. and downstream load components After translation, the number of strokes is determined. Stroke number corresponding to downstream load component When consistent, the upstream and downstream load components after translation are used as the stroke-aligned load components between adjacent workstations for the same strip unit number.

[0171] The stroke alignment load component is expressed as:

[0172]

[0173] in, Indicates the material strip unit number Upstream workstation number Downstream workstation number and standard phase sampling point number The corresponding stroke alignment load component.

[0174] S133.3: Based on the stroke alignment load component, calculate the load difference between adjacent workstation numbers and generate the transfer state value between adjacent workstations.

[0175] In one specific embodiment, the impulse alignment load component is read. The upstream and downstream load components are translated and the load difference between adjacent workstations is calculated for the same strip unit number.

[0176] The transition state value between adjacent workstations is represented as follows:

[0177]

[0178] in, Indicates the material strip unit number Upstream workstation number Downstream workstation number and standard phase sampling point number The corresponding transition status value between adjacent workstations.

[0179] It should be noted that the transfer status value between adjacent workstations reflects the load difference generated by the movement of the workstation load component as the same material belt unit number moves from the upstream workstation number to the downstream workstation number.

[0180] S134: Based on the transfer state value and the station load component, the screening belt transfers the load value and the station itself load value, generates the dwell state value within the same station, and generates station load attribution data through the transfer state value and the dwell state value.

[0181] In one specific embodiment, for the same workstation number and standard phase sampling point number Read the station load components corresponding to different material strip unit numbers in consecutive strokes. And read the workstation number. The transition state value.

[0182] When there is a load component in the workstation load that enters the current workstation from the upstream workstation number along with the material conveyor unit number, the corresponding load component is recorded as the material conveyor load value.

[0183] The load value transmitted by the conveyor belt is expressed as:

[0184]

[0185] in, Indicates the stroke number is Workstation number is The standard phase sampling points are numbered as follows: The corresponding load value transmitted by the material belt at that time Indicates the material strip unit number From the upstream work station number Enter workstation number The corresponding transition state value at that time.

[0186] The load value of the station itself is obtained by subtracting the load value transmitted by the conveyor belt from the load component of the station.

[0187] The self-load value of the workstation is expressed as:

[0188]

[0189] in, Indicates the stroke number is Workstation number is The standard phase sampling points are numbered as follows: The corresponding workstation's own load value at that time.

[0190] For the same workstation number Read the self-load value of the station in consecutive strokes, and calculate the difference of the self-load value of the station between adjacent strokes to obtain the dwell state value within the same station.

[0191] The dwell status value within the same workstation is represented as follows:

[0192]

[0193] in, Indicates the stroke number is Workstation number is The standard phase sampling points are numbered as follows: The dwell status value within the same workstation corresponding to the time.

[0194] Based on the transfer status value, the residence status value, the load value transferred by the conveyor belt, and the load value of the station itself, the station load attribution data is generated.

[0195] The workstation load attribution data is represented as follows:

[0196]

[0197] in, This indicates the data attribution of workstation loads.

[0198] It should be noted that: if the workstation number If there is no corresponding upstream station number entering the load section, the load value transmitted by the conveyor belt is zero, and the load value of the station itself is equal to the load component of the station.

[0199] S14: Determine the wear source station based on the station load attribution data, and correct the corresponding station load component of the downstream station through the wear source station to generate the wear state value of each station. Based on the wear state value of each station and the station failure boundary data, generate the remaining available strokes of each station.

[0200] In one specific embodiment, the station load attribution data includes the belt-transmitted load value and the station's own load value. The belt-transmitted load value represents the load portion that enters the downstream station number along with the belt unit number, while the station's own load value represents the load portion that remains fixed under the same station number. Based on the distribution of these two values ​​in consecutive strokes, the wear source station can be identified, and the load portion formed by the upstream station number in the downstream station number can be eliminated.

[0201] Specifically, the steps for generating the remaining available strokes for each workstation are as follows:

[0202] S141: Based on the workstation load attribution data, filter the workstation numbers that do not have upstream conveyor load values ​​but generate downstream conveyor load values ​​to determine the wear source workstations.

[0203] In one specific embodiment, for each workstation number Read the corresponding material belt transfer load value from the workstation load attribution data. and the load value of the workstation itself .

[0204] If the workstation number The conveyor belt load value is zero, and the station number is... The corresponding workstation's own load value increases in the same direction during consecutive strokes, while the downstream workstation number has a relationship with the workstation number. The corresponding material belt load value will be used to assign the workstation number. The workstation was identified as a source of wear.

[0205] The increment of the workstation's own load value is expressed as:

[0206]

[0207] in, Indicates the stroke number is Workstation number is The standard phase sampling points are numbered as follows: The increment of the load value of the corresponding workstation at that time.

[0208] In one specific embodiment, when three consecutive strokes If all values ​​are greater than zero, and there is a material conveyor load value downstream of the station number, then the station number will be... As a wear source station, the number of consecutive punches can also be set according to mold trial data or production cycle stability.

[0209] The wear source station is represented as:

[0210]

[0211] in, This indicates the station number corresponding to the wear source station.

[0212] It should be noted that the wear source station is not determined based on the peak value of a single impact, but rather on the continuous increment of the station's own load value under the same station number, as well as the result of the load value transmitted by the conveyor belt to the downstream station number.

[0213] S142: The load value is transferred through the material belt corresponding to the wear source station, and the load component of the station corresponding to the downstream station number is subtracted to generate the corrected station load component.

[0214] Specifically, the steps for generating the corrected workstation load components are as follows:

[0215] S142.1: Based on the wear source station and station sequence number, filter the station numbers located downstream of the wear source station to obtain the downstream station numbers;

[0216] In one specific embodiment, the wear source station is read. The corresponding workstation sequence number is denoted as And read the workstation sequence number corresponding to other workstation numbers, and record it as... .when At that time, the corresponding workstation number will be... Select as downstream workstation number.

[0217] The downstream workstation number is represented as follows:

[0218]

[0219] in, This indicates the downstream workstation number.

[0220] S142.2: By transmitting data and downstream station number through the material belt unit, read the corresponding stroke number of the material belt transmission load value of the wear source station under the downstream station number, and obtain the downstream transmission load value.

[0221] In one specific embodiment, the data transmitted by the conveyor belt unit from the wear source station is read. Enter downstream workstation number Material strip unit number And read the corresponding feed punch difference value. When the material belt unit number In the stroke number Located at the wear source station and in the stroke number Downstream workstation number At that time, the corresponding load value transmitted by the material belt is read.

[0222] The downstream transmitted load value is expressed as:

[0223]

[0224] in, Indicates the wear source workstation The corresponding material belt load value is entered into the downstream station number. Afterwards, in the stroke number and standard phase sampling point number The corresponding downstream transmitted load value.

[0225] S142.3: Based on the downstream transmitted load value, subtract the load component corresponding to the downstream workstation number to generate the corrected workstation load component.

[0226] In one specific embodiment, the downstream workstation number is read. Corresponding workstation load components and read the downstream transmitted load value The downstream transmitted load value is subtracted from the station load component to generate the corrected station load component.

[0227] The corrected workstation load components are expressed as follows:

[0228]

[0229] in, Indicates the stroke number is Downstream workstation number is The standard phase sampling points are numbered as follows: The corresponding corrected station load component.

[0230] It should be noted that: for non-downstream station numbers, the corrected station load component is equal to the station load component; for downstream station numbers, the corrected station load component removes the load portion transmitted from the wear source station along with the conveyor unit number.

[0231] S143: Based on the corrected station load components and the station's own load value, calculate the cumulative wear value corresponding to each station number within a continuous stroke, and generate the wear status value of each station.

[0232] In one specific embodiment, for each workstation number and standard phase sampling point number Read the corrected workstation load components and the load value of the workstation itself The corrected station load component is weighted and calculated with the station's own load value to obtain the wear state value for a single stroke.

[0233] The wear condition value for a single stroke is expressed as follows:

[0234]

[0235] in, Indicates the stroke number is Workstation number is The standard phase sampling points are numbered as follows: The corresponding wear state value per single stroke at that time. This indicates the normal load adjustment amount. The range of values ​​is The normal load repair quantity is determined based on the station load components and actual wear measurement results during the trial molding stage.

[0236] The wear status values ​​of each single stroke within a continuous stroke are accumulated to generate the wear status values ​​for each station.

[0237] The wear status values ​​for each workstation are represented as follows:

[0238]

[0239] in, Indicates the workstation number is In the stroke number To the next number The corresponding wear status values ​​for each workstation are as follows: Indicates the current stroke number. This indicates the number of standard phase sampling points.

[0240] It should be noted that when the wear state value of a single stroke needs to be compared with the failure load values ​​of different workstations, the wear state value of the single stroke is normalized. The normalized wear state value of a single stroke is expressed as follows:

[0241]

[0242] in, This represents the normalized wear state value per stroke. Indicates workstation number The lower limit of the wear condition value per single punch during the trial molding stage. Indicates workstation number The upper limit of the single-stroke wear state value when approaching maintenance condition. The normalized range of the single-stroke wear state value is as follows: .

[0243] S144: Based on the wear status value and failure load value of each station, the stroke number of each station number that reaches the failure load value is recursively calculated to generate the remaining available strokes for each station.

[0244] In one specific embodiment, the current stroke number is read. Corresponding wear status values ​​for each workstation and read the workstation number. Corresponding workstation failure load value The recursive step size of wear at each station is calculated based on the increment of wear status values ​​within the most recent consecutive strokes.

[0245] The recursive step size for workstation wear is expressed as follows:

[0246]

[0247] in, Indicates the workstation number is The corresponding wear regression step size for the workstation. This indicates the number of historical impulses involved in the recursive step size calculation. It is determined based on the stability of the stamping cycle and the length of the production batch.

[0248] Based on the wear step size of the workstation, the strokes are recursively calculated to obtain the stroke number as follows: The recursive wear state value at that time.

[0249] The recursive wear state value is expressed as:

[0250]

[0251] in, This indicates the number of strokes counted sequentially from the current stroke number. Indicates the workstation number is In the recursive stroke numbering The corresponding recursive wear state value.

[0252] When the recursive wear state value Failure load value at the workstation At that time, the corresponding As workstation number The remaining number of strokes available for each corresponding workstation.

[0253] The remaining strokes at each workstation can be represented as follows:

[0254]

[0255] in, Indicates the workstation number is The remaining number of strokes available for each corresponding workstation.

[0256] It should be noted that: if the wear increment of the workstation is... If the wear value is zero, the current wear status value of each station remains unchanged, and the remaining available strokes of each station are marked as to be collected again; if the wear recursion step size of the station is zero, the wear status value of each station remains unchanged. If the value is less than zero, the wear recursion step size of the station within the most recent stable production strokes that is greater than zero will be used for the recursion. The stable production stroke range of the wear recursion step size is determined based on the production batch switching record.

[0257] The above embodiments are only used to illustrate the technical methods of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical methods of the present invention without departing from the spirit and scope of the technical methods of the present invention.

Claims

1. A method for intelligently predicting the wear state of a stamping die, characterized in that, The method includes: Collect multi-point punching force data, slider phase data, strip feeding data, station layout data and station failure boundary data of continuous punches, and generate strip unit transfer data based on strip feeding data and station layout data; Based on multi-point punching force data and slider phase data, phase punching force data is obtained by registration. According to the phase punching force data and station layout data, the superimposed punching force value within the same punching cycle is split to generate station load components. Based on the data transmitted by the conveyor belt unit and the load components of the workstation, the transfer status value between adjacent workstations and the dwell status value within the same workstation are generated. The workstation load attribution data is then generated using the transfer status value and the dwell status value. The wear source station is determined based on the workstation load attribution data, and the corresponding workstation load component of the downstream workstation is corrected through the wear source station to generate the wear state value of each workstation. Based on the wear state value of each workstation and the workstation failure boundary data, the remaining available strokes of each workstation are generated.

2. The intelligent prediction method for the wear state of a stamping die according to claim 1, characterized in that, The multi-point impact force data includes the impact number, force measurement position number, force measurement position coordinates, sampling time, and impact force value. The slider phase data includes the impact number, sampling time, slider phase value, upper dead point mark, and lower dead point mark. The material feeding data includes the impact number, feeding step distance value, material strip front end position value, and material strip unit length value. The station layout data includes the station number, station sequence number, station center coordinates, and station action length value. The station failure boundary data includes the station number and station failure load value.

3. The intelligent prediction method for the wear state of a stamping die according to claim 2, characterized in that, The steps for generating the data transmission unit are as follows: Based on the position value of the front end of the material strip and the length value of the material strip unit, divide the material strip position segment within the consecutive strokes and generate the material strip unit number; The feeding distance between adjacent strokes is calculated by using the feeding step distance and the position of the front end of the conveyor belt, thus obtaining the feeding distance per stroke. Based on the center coordinates of the workstation and the working length value, the material strip coverage area corresponding to each workstation number is determined, and the workstation coverage area is generated. Based on the material belt unit number, the feed distance value per stroke, and the station coverage area, write the station number corresponding to the material belt unit number for each stroke to generate material belt unit transfer data.

4. The intelligent prediction method for the wear state of a stamping die according to claim 3, characterized in that, The steps for generating station load components are as follows: Based on the stroke number and sampling time, the stroke force value and the slider phase value are matched to generate force phase pairing data; By using the force measurement phase pairing data, the upper dead point mark, and the lower dead point mark, the impact force value under each force measurement position number is corrected, and phase impact force data is generated. Based on the center coordinates of the workstation and the working length value, the workstation numbers that participate in the stamping contact under the same slider phase value are filtered to obtain the participating workstation numbers; Based on the phase impact force data and the participating workstation number, the impact force values ​​superimposed within the same stroke are split to generate the workstation load components.

5. The intelligent prediction method for the wear state of a stamping die according to claim 4, characterized in that, The steps to generate phase impulse data are as follows: Based on the force phase pairing data, the impulse force value corresponding to each sampling time under the same impulse number is read to obtain the impulse force value of the impulse. By using the top dead center mark and the bottom dead center mark, the slider phase value corresponding to the punch force value is calibrated to obtain the standard slider phase value; Based on the standard slider phase value and force measurement position number, the values ​​of the punching force are rearranged under different force measurement position numbers to generate phase punching force data.

6. The intelligent prediction method for the wear state of a stamping die according to claim 5, characterized in that, The steps to generate workstation load attribution data are as follows: Based on the data transmitted by the material belt unit and the load component of the workstation, the workstation load component corresponding to the same material belt unit number when passing through the adjacent workstation number is read to obtain the cross-workstation load component. By using the feeding step distance value and the station sequence number, the number of strokes from the upstream station number to the downstream station number of the same material strip unit number is calculated to obtain the feeding stroke difference. Based on the cross-station load component and the difference in feeding strokes, the load difference between adjacent station numbers for the same material strip unit number is calculated, and the transition state value between adjacent stations is generated. Based on the transfer status value and the load component of the workstation, the load value transferred by the screening belt and the load value of the workstation itself are used to generate the dwell status value within the same workstation, and the workstation load attribution data is generated through the transfer status value and the dwell status value.

7. The intelligent prediction method for the wear state of a stamping die according to claim 6, characterized in that, The steps for generating transition state values ​​between adjacent workstations are as follows: Based on the data transmitted by the material belt unit, read the upstream station number and downstream station number corresponding to the same material belt unit number to obtain the adjacent station number pair; By using the difference in feeding strokes, the stroke numbers corresponding to the load components of the next spanning station are calibrated to match the adjacent station numbers, thus obtaining the stroke-aligned load components. Based on the stroke alignment load component, the load difference between adjacent workstation numbers is calculated, and the transfer state value between adjacent workstations is generated.

8. The intelligent prediction method for the wear state of a stamping die according to claim 7, characterized in that, The steps to obtain the stroke alignment load components are as follows: Based on the adjacent workstation number pairs, read the upstream load component corresponding to the upstream workstation number and the downstream load component corresponding to the downstream workstation number to obtain the cross-workstation load pairing value. By using the difference in feeding strokes, the stroke number corresponding to the upstream load component in the span load pairing value is shifted to obtain the shifted upstream load component. Based on the upstream and downstream load components after translation, load values ​​with the same stroke number are selected to obtain the stroke-aligned load components.

9. The intelligent prediction method for the wear state of a stamping die according to claim 8, characterized in that, The steps to generate the remaining available strokes for each workstation are as follows: Based on the workstation load attribution data, the workstation numbers that do not have upstream conveyor load values ​​but generate downstream conveyor load values ​​are filtered out to determine the wear source workstations. By transferring the load value through the material belt corresponding to the wear source station, the load component of the station corresponding to the downstream station number is subtracted to generate the corrected station load component. Based on the corrected station load components and the station's own load value, calculate the cumulative wear value corresponding to each station number within consecutive strokes, and generate the wear status value of each station. Based on the wear status value and failure load value of each workstation, the stroke number of each workstation that reaches the failure load value is recursively calculated to generate the remaining available strokes for each workstation.

10. The intelligent prediction method for the wear state of a stamping die according to claim 9, characterized in that, The steps for generating the corrected workstation load components are as follows: Based on the wear source station and station sequence number, filter the station numbers located downstream of the wear source station to obtain the downstream station numbers; By transmitting data and downstream station number through the material belt unit, the corresponding stroke number under the downstream station number is read from the material belt transmission load value corresponding to the wear source station to obtain the downstream transmission load value. Based on the downstream transmitted load value, the load component corresponding to the downstream workstation number is subtracted to generate the corrected workstation load component.

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