A driving disc processing broken tool detection device

Abstract

The utility model relates to machining detection technical field, and disclose a kind of drive plate processing broken tool detection device, including rack, the vertical installation of tool shank is installed in one side below the rack.This drive plate processing broken tool detection device, for the complex curved surface of drive plate class parts and high-precision inclined hole processing demand, through the collaborative monitoring of three-axis acceleration vibration sensor and high-sensitivity acoustic emission sensor, constructs multidimensional tool state perception system, three-axis acceleration vibration sensor real-time capture tool in drive plate curved surface milling, inclined hole drilling and other processes X, Y, Z three directions vibration acceleration change, can acutely perceive abnormal vibration signal generated by tool fracture, acoustic emission sensor utilizes piezoelectric ceramic material, can capture the high-frequency elastic wave generated when tool microcrack expands, two kinds of sensor data complement each other, compared with single detection mode, so that broken tool detection accuracy improves, effectively avoids missed detection, misjudgment.

Description

Technical Field

[0001] This utility model relates to the field of mechanical processing and testing technology, specifically to a device for detecting broken tools in drive disc machining. Background Technology

[0002] During the machining of drive discs, tool breakage can not only lead to workpiece scrap, but may also cause machine tool damage or even safety accidents. Therefore, efficient and accurate tool breakage detection technology is the key to ensuring machining quality and production safety.

[0003] The existing patent document CN215035932U provides a machine tool broken tool detection device. This utility model can quickly position and fix the cutting tool through the positioning groove, and has high stability. With the assistance of the detection component and the elastic push of the positioning spring, the cutting tool is reinforced and the local stress on the cutting tool can be absorbed. When the cutting tool breaks, the cutting tool separates from the mounting base. Under the elastic pull of the limit spring, the two sets of symmetrically arranged detection plates are aligned and then the two sets of trigger switches are contacted and triggered, so that the alarm is activated, which can remind the staff and ensure the safety of machine tool operation.

[0004] However, existing broken tool detection devices suffer from a lack of diverse detection methods. For example, vibration detection can only capture changes in the frequency and amplitude of tool vibration. However, under complex machining conditions, interference such as cutting force fluctuations and machine tool resonance can easily lead to misjudgments. While current detection can reflect changes in spindle motor load, it is difficult to detect subtle anomalies in the initiation stage of microcracks in the tool, resulting in a significant blind spot and low detection accuracy. This makes it difficult to meet the stringent requirements of micron-level precision control in drive disk machining, leading to a high scrap rate and seriously hindering the industry's intelligent and high-precision development process. Utility Model Content

[0005] (a) Technical problems to be solved

[0006] The purpose of this invention is to provide a tool breakage detection device for drive disc machining, so as to solve the problem mentioned in the background art that the existing tool breakage detection devices have a single detection method.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, this utility model provides the following technical solution: a drive disc machining tool breakage detection device, comprising a frame, a tool holder vertically mounted on one side below the frame, and a machining head detachably connected to the bottom end of the tool holder;

[0009] A vibration sensor, which is a triaxial accelerometer, is installed on one side of the tool holder. An acoustic emission sensor, which is made of high-sensitivity piezoelectric ceramic material, is installed below the frame.

[0010] As a further improvement to the above solution, a connecting plate is provided on one side of the vibration sensor, and a fastening bolt is provided on the connecting plate. The fastening bolt passes through the connecting plate and engages with the pre-threaded hole of the tool holder.

[0011] As a further improvement to the above solution, a connecting block is provided on one side of the acoustic emission sensor, a mating block is provided on the outer surface of the connecting block, and a connecting sleeve is provided at the bottom of the frame.

[0012] As a further improvement to the above solution, the connecting sleeve is provided with a mating groove inside, and the mating block can slide into the mating groove in a horizontal direction.

[0013] As a further improvement to the above solution, a blind hole is opened at the top of the connecting block as a groove, a positioning spring is built into the groove, and a connecting piece is fixedly connected to the top of the positioning spring.

[0014] As a further improvement to the above solution, a connecting rod is vertically fixed at the bottom end of the connecting piece, the connecting rod is located inside the positioning spring, and the upper surface of the connecting sleeve is provided with a connecting groove that matches the connecting rod.

[0015] As a further improvement to the above solution, the connecting piece is movably connected to the connecting groove, and an audible and visual alarm is provided at the top of the frame. The audible and visual alarm is electrically connected to a vibration sensor and an acoustic emission sensor.

[0016] Compared with the prior art, the beneficial effects of this utility model are:

[0017] 1. This broken tool detection device for drive disk machining is designed for the complex curved surfaces and high-precision oblique hole machining requirements of drive disk parts. It constructs a multi-dimensional tool status perception system through the collaborative monitoring of a triaxial acceleration vibration sensor and a high-sensitivity acoustic emission sensor. The triaxial acceleration vibration sensor captures the changes in vibration acceleration of the tool in the X, Y, and Z directions in real time during processes such as milling curved surfaces and drilling oblique holes on the drive disk. It can sensitively detect abnormal vibration signals caused by tool breakage. The acoustic emission sensor uses piezoelectric ceramic material to capture high-frequency elastic waves generated when microcracks propagate in the tool. The data from the two sensors complement each other, which improves the accuracy of broken tool detection compared to a single detection method and effectively avoids missed detections and false detections.

[0018] 2. This drive disk machining tool breakage detection device, through a unique sensor mounting and fixing structure, ensures detection stability and reliability. The vibration sensor is firmly installed on the tool holder through the cooperation of the connecting plate and fastening bolts, ensuring that the sensor and the tool vibrate synchronously during the machining process, avoiding signal acquisition deviation due to loosening. The sliding cooperation of the acoustic emission sensor's connecting block, docking block and connecting sleeve, docking groove, as well as the elastic positioning structure composed of positioning spring, connecting plate and connecting rod, allows it to be firmly installed at the bottom of the frame, and can also adapt to a certain degree of vibration and impact, preventing the sensor from falling off or shifting, and ensuring continuous and stable detection.

[0019] 3. This drive disk machining tool breakage detection device achieves rapid response and handling of faults through the electrical connection between the audible and visual alarm and the sensor. Once the vibration sensor or acoustic emission sensor detects an abnormal signal, it is transmitted to the audible and visual alarm via the circuit. The alarm will then emit a buzzing sound and a flashing red light to warn the operator. The operator can quickly detect the tool failure, stop the machine in time, reduce workpiece scrap and machine tool damage caused by tool breakage, reduce production costs, and improve production safety and processing efficiency. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0021] Figure 2 This is a three-dimensional structural diagram of the vibration sensor of this utility model;

[0022] Figure 3 This is a three-dimensional structural diagram of the acoustic emission sensor of this utility model;

[0023] Figure 4 This is a three-dimensional structural diagram of the connecting block of this utility model;

[0024] Figure 5 This is a three-dimensional structural diagram of the connecting sleeve of this utility model.

[0025] In the diagram: 1. Frame; 2. Tool holder; 3. Machining head; 4. Vibration sensor; 5. Acoustic emission sensor; 6. Connecting plate; 7. Fastening bolt; 8. Connecting block; 9. Butt joint block; 10. Connecting sleeve; 11. Butt joint groove; 12. Groove; 13. Positioning spring; 14. Connecting piece; 15. Connecting rod; 16. Connecting groove; 17. Audible and visual alarm. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0027] Please see Figure 1 - Figure 5 This utility model provides a technical solution: a drive disk processing tool breakage detection device, including a frame 1, a tool holder 2 vertically installed on one side below the frame 1, and a processing tool head 3 detachably connected to the bottom end of the tool holder 2;

[0028] A vibration sensor 4 is installed on one side of the tool holder 2. The vibration sensor 4 is a triaxial accelerometer. An acoustic emission sensor 5 is installed under the frame 1. The acoustic emission sensor 5 is made of high-sensitivity piezoelectric ceramic material.

[0029] During the machining process of the drive disc, vibration sensor 4 and acoustic emission sensor 5 simultaneously enter working mode. The triaxial accelerometer (vibration sensor 4) is firmly installed on one side of the tool holder 2, monitoring the vibration acceleration data of the tool in the X, Y, and Z directions in real time during machining. During normal machining, the tool vibration is within a stable and regular range. Once the tool experiences accelerated wear, chipping, or even breakage, its vibration frequency and amplitude will change abruptly. Vibration sensor 4 sensitively captures these abnormal vibration signals. At the same time, acoustic emission sensor 5, made of high-sensitivity piezoelectric ceramic material, is kept at a distance of 10-20 cm from the tool to obtain the optimal acoustic emission signal. When microcracks propagate or break in the machining head 3, the stress concentration area inside the material will rapidly release energy in the form of elastic waves, generating acoustic waves. With its high sensitivity, the acoustic emission sensor 5 converts these elastic wave signals into electrical signals, completing the acquisition of acoustic emission signals. The analog signals acquired by the vibration sensor 4 and the acoustic emission sensor 5 are transmitted to the subsequent processing module through the built-in circuit. Since the signals acquired by the sensors are relatively weak and contain interference, they need to be preprocessed by the signal conditioning circuit, such as amplification and filtering, to improve the signal quality. The processed signals are transmitted to the data processing unit (which can be integrated into the frame 1 or connected to an external controller, not shown in the figure). The data processing unit uses a preset algorithm model to perform in-depth analysis of the vibration signal and the acoustic emission signal. By comparing the signal feature database during normal processing, it determines whether the tool is in normal working condition. Once the signal feature is found to exceed the normal threshold range, it is determined that the tool is abnormal and may have broken.

[0030] A connecting plate 6 is provided on one side of the vibration sensor 4. A fastening bolt 7 is provided on the connecting plate 6. The fastening bolt 7 passes through the connecting plate 6 and engages with the pre-set threaded hole of the tool holder 2. A connecting block 8 is provided on one side of the acoustic emission sensor 5. A mating block 9 is provided on the outer surface of the connecting block 8. A connecting sleeve 10 is provided at the bottom of the frame 1. A mating groove 11 is provided inside the connecting sleeve 10. The mating block 9 can slide into the mating groove 11 in the horizontal direction. A blind hole is opened at the top of the connecting block 8 as a groove 12. A positioning spring 13 is built into the groove 12. A connecting piece 14 is fixedly connected to the top of the positioning spring 13. A connecting rod 15 is vertically fixed to the bottom of the connecting piece 14. The connecting rod 15 is located inside the positioning spring 13. A connecting groove 16 is provided on the upper surface of the connecting sleeve 10 to match the connecting rod 15. The connecting piece 14 is movably connected to the connecting groove 16. An audible and visual alarm 17 is provided at the top of the frame 1. The audible and visual alarm 17 is electrically connected to the vibration sensor 4 and the acoustic emission sensor 5.

[0031] When the data processing unit determines that the tool has broken or is in an abnormal state, it immediately sends a trigger signal to the audible and visual alarm 17. Upon receiving the signal, the audible and visual alarm 17 quickly activates the alarm function, emitting a high-decibel buzzer and flashing red light to attract the operator's attention. At the same time, the alarm signal can also be transmitted to the machine tool control system to trigger the machine tool's automatic shutdown program, preventing further damage to the workpiece or machine tool failure caused by the broken tool, and minimizing production losses. The vibration sensor 4 is securely connected to the tool holder 2 through the connecting plate 6 and the fastening bolt 7, ensuring that the sensor can closely follow the tool vibration during processing and accurately collect vibration data, avoiding signal distortion due to loosening. In the installation structure of the acoustic emission sensor 5, the horizontal sliding cooperation between the docking block 9 and the docking groove 11 enables the sensor to be quickly installed and positioned. The elastic positioning structure composed of the positioning spring 13, the connecting piece 14, and the connecting rod 15 allows the sensor to be securely installed while adapting to vibration and impact during processing, preventing the sensor from shifting or falling off, and ensuring the continuity and stability of acoustic emission signal acquisition.

[0032] Working principle: During the machining process of the drive disc, the vibration sensor 4 and the acoustic emission sensor 5 simultaneously enter the working state. The triaxial accelerometer (vibration sensor 4) is firmly installed on one side of the tool holder 2, which monitors the vibration acceleration data of the tool in the X, Y, and Z directions in real time during machining. During normal machining, the tool vibration is in a stable and regular range. Once the tool experiences accelerated wear, chipping, or even breakage, its vibration frequency and amplitude will change abruptly. The vibration sensor 4 sensitively captures these abnormal vibration signals. At the same time, the acoustic emission sensor 5, made of high-sensitivity piezoelectric ceramic material, is installed at the bottom of the frame 1. Through the cooperation of the connecting block 8, the mating block 9, the connecting sleeve 10, and the mating groove 11, as well as the positioning spring 13 and the connecting piece 1, the sensor works in conjunction with the connecting block 8, the mating block 9, the connecting sleeve 10, and the mating groove 11. The elastic positioning structure formed by vibration sensor 4 and connecting rod 15 is securely positioned, and the distance between acoustic emission sensor 5 and the cutting tool is maintained within the range of 10-20cm to obtain the optimal acoustic emission signal. When microcracks propagate or break in the machining head 3, the stress concentration area inside the material will rapidly release energy in the form of elastic waves. Acoustic emission sensor 5, with its high sensitivity, converts these elastic wave signals into electrical signals, completing the acquisition of acoustic emission signals. The analog signals acquired by vibration sensor 4 and acoustic emission sensor 5 are transmitted to the subsequent processing module through built-in circuitry. Since the signals acquired by the sensors are relatively weak and contain interference, they need to undergo preprocessing such as amplification and filtering by the signal conditioning circuit to improve signal quality. The processed signal is then transmitted to the digital processing module. The data processing unit (which can be integrated into the frame 1 or connected to an external controller, not shown in the figure) uses a preset algorithm model to perform in-depth analysis of vibration and acoustic emission signals. By comparing the signal characteristic database during normal machining, it determines whether the tool is in normal working condition. Once the signal characteristics are found to exceed the normal threshold range, it is determined that the tool is abnormal and may have broken. When the data processing unit determines that the tool has broken or is in an abnormal state, it immediately sends a trigger signal to the audible and visual alarm 17. After receiving the signal, the audible and visual alarm 17 quickly activates the audible and visual alarm function, emitting a high-decibel buzzer and flashing red light to attract the operator's attention. At the same time, the alarm signal can also be synchronously transmitted to the machine tool control system to trigger... The machine tool automatic shutdown program prevents further damage to the workpiece or machine tool failure due to tool breakage, minimizing production losses. Vibration sensor 4 is securely connected to tool holder 2 via connecting plate 6 and fastening bolts 7, ensuring that the sensor closely follows tool vibration during processing and accurately collects vibration data, avoiding signal distortion due to loosening. In the mounting structure of acoustic emission sensor 5, the horizontal sliding fit between docking block 9 and docking groove 11 enables rapid installation and positioning of the sensor. The elastic positioning structure composed of positioning spring 13, connecting piece 14, and connecting rod 15 allows the sensor to be securely installed while adapting to vibration and impact during processing, preventing sensor displacement or detachment, and ensuring the continuity and stability of acoustic emission signal acquisition.

[0033] Finally, it should be noted that the above content is only used to illustrate the technical solution of this utility model, and is not intended to limit the scope of protection of this utility model. Simple modifications or equivalent substitutions made by those skilled in the art to the technical solution of this utility model do not depart from the essence and scope of the technical solution of this utility model.

Claims

1. A device for detecting broken tools during drive disc machining, comprising a frame (1), characterized in that: A tool holder (2) is vertically mounted on one side below the frame (1), and a processing head (3) is detachably connected to the bottom end of the tool holder (2). A vibration sensor (4) is installed on one side of the tool holder (2). The vibration sensor (4) is a triaxial accelerometer. An acoustic emission sensor (5) is installed below the frame (1). The acoustic emission sensor (5) is made of high-sensitivity piezoelectric ceramic material.

2. The drive disc machining tool breakage detection device according to claim 1, characterized in that: A connecting plate (6) is provided on one side of the vibration sensor (4), and a fastening bolt (7) is provided on the connecting plate (6). The fastening bolt (7) passes through the connecting plate (6) and engages with the pre-set threaded hole of the tool holder (2).

3. The drive disc machining tool breakage detection device according to claim 1, characterized in that: A connecting block (8) is provided on one side of the acoustic emission sensor (5), a docking block (9) is provided on the outer surface of the connecting block (8), and a connecting sleeve (10) is provided at the bottom of the frame (1).

4. The drive disc machining tool breakage detection device according to claim 3, characterized in that: The connecting sleeve (10) is provided with a docking groove (11) inside, and the docking block (9) can slide into the docking groove (11) in the horizontal direction.

5. The drive disc machining tool breakage detection device according to claim 3, characterized in that: The top of the connecting block (8) has a blind hole as a groove (12), and a positioning spring (13) is built into the groove (12). The top of the positioning spring (13) is fixedly connected to a connecting piece (14).

6. The drive disc machining tool breakage detection device according to claim 5, characterized in that: The bottom end of the connecting piece (14) is vertically fixed with a connecting rod (15), the connecting rod (15) is located inside the positioning spring (13), and the upper surface of the connecting sleeve (10) is provided with a connecting groove (16) that is adapted to the connecting rod (15).

7. The drive disc machining tool breakage detection device according to claim 5, characterized in that: The connecting piece (14) is movably connected to the connecting groove (16), and the top of the frame (1) is provided with an audible and visual alarm (17), which is electrically connected to the vibration sensor (4) and the acoustic emission sensor (5).

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