An on-line detection device for numerical control machine tools

Abstract

This utility model relates to the field of precision machining and inspection technology, and discloses an online inspection device for CNC machine tools, including a sensing and detection module, a data processing module, a dual-mode communication module, a display, and an alarm module. The sensing and detection module includes a laser displacement sensor, a vibration sensor group, and an infrared thermometer, which are installed on the machine tool to achieve coordinated monitoring of multiple physical quantities such as workpiece size, equipment vibration, and component temperature. The data processing module is connected to the sensing and detection module via an industrial bus. The data processing module includes a SoC control chip and a storage unit, with the storage unit electrically connected to the SoC control chip to complete real-time processing and storage of the detection data. The dual-mode communication module includes a dual-channel transmission interface, and the data processing module is used for efficient and stable data transmission. This device effectively improves machining quality and equipment reliability, has good adaptability, reduces installation and debugging difficulty, and optimizes production management efficiency.

Description

Technical Field

[0001] This utility model relates to the field of precision machining and testing technology, specifically to an online testing device for CNC machine tools. Background Technology

[0002] CNC machine tools, also known as numerical control machine tools, are a type of automated machining equipment equipped with a program control system. This program control system, based on Boolean logic, parses and processes programs containing control codes or other symbolic instructions, converting them into coded digital signals, which are then transmitted to the CNC unit via an information carrier. The CNC unit then processes and generates and outputs various control signals, precisely driving the movement of the machine tool's components, thereby achieving automated machining of parts according to the geometric shapes and dimensional parameters specified in the engineering drawings. In equipment inspection, traditional offline inspection devices require interrupting machine tool operation to perform inspection work. This non-real-time inspection mode significantly reduces production efficiency and fails to meet the requirements of modern manufacturing for continuous and efficient processing. Existing online inspection devices generally suffer from complex wiring architectures and low integration with CNC systems, resulting in inefficient data exchange between systems and insufficient collaborative capabilities. Furthermore, these devices lack dynamic adjustment mechanisms for sensor mounting positions, making it difficult to optimize the configuration of inspection perspective and accuracy in complex and ever-changing industrial processing environments, thus significantly reducing their environmental adaptability. Utility Model Content

[0003] In view of this, the present invention provides an online inspection device for CNC machine tools to solve the technical problems of traditional inspection devices being mostly offline, requiring machine downtime and affecting production efficiency; and existing online inspection devices having complex wiring and poor compatibility with CNC systems. Furthermore, the sensors in online inspection devices have fixed positions and cannot be adjusted, resulting in poor environmental adaptability.

[0004] To achieve the above objectives, this utility model provides the following technical solution: It mainly provides an online inspection device for CNC machine tools, comprising a sensing and detection module, a data processing module, and a dual-mode communication module. The sensing and detection module includes three key detection components: a laser displacement sensor, a vibration sensor group, and an infrared thermometer. These components are positioned at key parts of the machine tool. The laser displacement sensor is mounted near the spindle via a multi-degree-of-freedom adjustable bracket, while the infrared thermometer is mounted near the cutting tool via an adsorption mechanism and a shock-absorbing structure. The laser displacement sensor, based on the triangulation principle, can achieve high-precision displacement measurement at the micrometer level, used for real-time monitoring of workpiece dimensional changes and tool wear during machine tool processing. The vibration sensor group includes two vibration sensors: one fixed to the spindle box bearing seat via a threaded connection to monitor the vibration state of the spindle system, and the other fixed to the side of the machine tool bed track to acquire basic vibration data during machine tool operation. The two sensors work together to provide multi-dimensional data support for machine tool dynamics analysis. The infrared thermometer utilizes the thermal radiation effect to non-contactly measure the temperature of key machine tool components, promptly detecting abnormal temperature rises caused by overload, poor lubrication, etc. The data processing module and the sensing module achieve stable data transmission via an industrial bus. This module uses a SoC control chip as its core processing unit and integrates a storage unit. The SoC control chip can perform fast filtering, noise reduction, and feature extraction on the multi-source detection data transmitted by the sensing module. The storage unit is electrically connected to the SoC control chip and uses a large-capacity non-volatile memory, which can store the raw detection data and processed feature data for a long time with high reliability, facilitating subsequent data analysis and fault tracing.

[0005] The dual-mode communication module includes both wired and wireless transmission interfaces. The wired transmission channel adopts the industrial Ethernet standard, supporting high-speed data transmission of 1000Mbps, suitable for production site monitoring scenarios with extremely high requirements for data real-time performance and stability. The wireless transmission channel uses 5G communication technology, ensuring reliable data communication between the system and the remote control host in complex industrial environments. The data processing module is electrically connected to the dual-mode communication module, enabling efficient output and remote transmission of processed data. Furthermore, the laser displacement sensor is mounted on the machine tool via a multi-degree-of-freedom adjustable bracket, and the infrared thermometer is mounted on the machine tool via a strong magnet adsorption mechanism. A shock-absorbing structure connects the strong magnet and the infrared thermometer.

[0006] Furthermore, the multi-degree-of-freedom adjustable bracket includes a pitch angle adjustment mechanism and an axial telescopic rod. The pitch angle adjustment mechanism uses a worm gear drive. The vibration damping structure includes a support plate, a disc spring, a hydraulic damper, and a silicone buffer layer. One end of the disc spring is fixed to the support plate, and the other end is connected to the hydraulic damper, which is fitted with a silicone buffer layer. When the machine tool vibrates, the disc spring first provides initial buffering, the hydraulic damper further absorbs and attenuates vibration energy through its damping characteristics, and the silicone buffer layer provides final buffering and protection, ensuring that the infrared thermometer can perform temperature measurements in a stable environment, thus improving the accuracy and reliability of the measurements.

[0007] Furthermore, the vibration sensor group adopts a triaxial MEMS sensor. The vibration sensor group includes two vibration sensors. One vibration sensor is fixed to the spindle box bearing seat by a threaded connection, and the other vibration sensor is fixed to the side of the machine tool bed track by a threaded connection.

[0008] Furthermore, the laser displacement sensor is electrically connected to the SoC control chip through a signal conditioning circuit, and the vibration sensor group and infrared thermometer are both electrically connected to the SoC control chip through a serial port.

[0009] Furthermore, it also includes a display and an alarm module. The display is electrically connected to the SoC control chip, and the alarm module includes an LED light group, a voice alarm, and a buzzer alarm, all of which are electrically connected to the SoC control chip.

[0010] As can be seen from the above technical solution, the main advantages of this utility model include: 1. This utility model uses a sensing and detection module to monitor the machine tool's operating status in real time from multiple dimensions such as displacement, vibration, and temperature. Combined with a SoC control chip, it can achieve micron-level precision detection, effectively improving processing quality and equipment reliability. 2. The multi-degree-of-freedom adjustable bracket of the laser displacement sensor and the shock-absorbing adsorption mechanism of the infrared thermometer enable the device to adapt to different types of machine tools and complex and ever-changing industrial environments, reducing installation and debugging difficulty and improving equipment versatility. Furthermore, the configuration of the display and alarm module enables user-friendly human-machine interaction, improving fault response speed and optimizing production management efficiency.

[0011] 3. The device has good compatibility and can be integrated with different types of CNC machine tools to meet the needs of different users. Attached Figure Description

[0012] The accompanying drawings, which form part of this utility model, are used to provide a further understanding of the utility model. The illustrative embodiments of the utility model and their descriptions are used to explain the utility model and do not constitute an undue limitation of the utility model. In the drawings: Figure 1 This is a schematic diagram of the composition structure of this utility model.

[0013] Figure 2 This is a schematic diagram of another component structure of this utility model. Detailed Implementation

[0014] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0015] This embodiment provides an online CNC machine tool monitoring device that can monitor the machine tool's operating status in real time from multiple dimensions, adapt to different machine tool models and complex and ever-changing industrial environments, improve fault response speed, and optimize production management efficiency. Figure 1 and Figure 2 As shown, this online inspection device for CNC machine tools is composed of several key units working together, closely interconnected. Specifically, it includes a sensing and detection module, a data processing module, and a dual-mode communication module. The sensing and detection module includes a laser displacement sensor, a vibration sensor group, and an infrared thermometer. The laser displacement sensor is mounted on the machine tool via a multi-degree-of-freedom adjustable bracket, and the infrared thermometer is mounted on the machine tool via a strong magnet adsorption mechanism. A shock-absorbing structure connects the strong magnet and the infrared thermometer. The data processing module is connected to the sensing and detection module via an industrial bus. The data processing module includes a SoC control chip and a storage unit, with the storage unit electrically connected to the SoC control chip. The dual-mode communication module includes wired and wireless dual-channel transmission interfaces. The data processing module is electrically connected to the dual-mode communication module, enabling efficient output and remote transmission of processed data. The dual-mode communication module includes wired and wireless dual-channel transmission interfaces. The wired transmission channel adopts the industrial Ethernet standard and supports 1000Mbps high-speed data transmission, which is suitable for production site monitoring scenarios with extremely high requirements for data real-time performance and stability. The wireless transmission channel adopts 5G communication technology, which can ensure the reliability of data communication between the system and the remote control host in complex industrial environments, so as to realize remote monitoring and data sharing.

[0016] Specifically, to enhance the environmental adaptability and installation flexibility of the sensing module, the laser displacement sensor is mounted on the machine tool via a multi-degree-of-freedom adjustable bracket. This bracket includes a pitch angle adjustment mechanism and an axial telescopic rod. The pitch angle adjustment mechanism uses a worm gear drive with a self-locking function, enabling high-precision angle adjustment within a ±90° range, facilitating adjustment of the detection angle in complex machining scenarios. The axial telescopic rod can extend and retract within a range of 0-200mm to meet the needs of different detection distances and angles. The infrared thermometer is mounted on the machine tool via a strong magnet adsorption mechanism. A vibration damping structure connects the strong magnet and the infrared thermometer, consisting of a support plate, a disc spring, a hydraulic damper, and a silicone buffer layer. One end of the disc spring is fixed to the support plate, and the other end is connected to the hydraulic damper. The surface of the hydraulic damper is covered with a silicone buffer layer, which effectively attenuates high-frequency vibrations generated during machine tool operation, ensuring the stability and accuracy of the infrared thermometer's measurement data.

[0017] In this embodiment, a laser displacement sensor is mounted near the spindle via a multi-degree-of-freedom adjustable bracket, and an infrared thermometer is mounted near the tool via an adsorption mechanism and a shock-absorbing structure. The vibration sensor group employs a triaxial MEMS sensor. The laser displacement sensor, based on the triangulation principle, enables high-precision displacement measurement at the micrometer level, used for real-time monitoring of workpiece dimensional changes and tool wear during machine tool processing. The vibration sensor group includes two vibration sensors: one fixed to the spindle box bearing housing via a threaded connection, and the other fixed to the side of the machine tool bed track via a threaded connection. These sensors are used to monitor the vibration state of the spindle system and detect basic vibration data during machine tool operation, respectively. Working together, they provide multi-dimensional data support for machine tool dynamics analysis. The infrared thermometer utilizes the thermal radiation effect to non-contactly measure the temperature of key machine tool components, promptly detecting abnormal temperature rises caused by overload, poor lubrication, etc.

[0018] The laser displacement sensor is electrically connected to the SoC control chip through a signal conditioning circuit, while the vibration sensor group and the infrared thermometer are both electrically connected to the SoC control chip through a serial port.

[0019] In this embodiment, the signal conditioning circuit includes an operational amplifier, an anti-aliasing filter, and an ADC conversion module. The operational amplifier, anti-aliasing filter, and ADC conversion module are electrically connected in sequence. The SoC control chip is a Xilinx Zynq-7020SoC (ARM Cortex-A9 + FPGA), the laser displacement sensor is a ZLDS103, the infrared thermometer is an AMG8833, and the interface type is I2C. It is connected to the input port of the FPGA through the data communication interface SCL / SDA. The vibration sensor is an ADXL355, which is connected to the SoC control chip through the SPI digital interface.

[0020] This online inspection device is also equipped with a display and an alarm module. The display is electrically connected to the SoC control chip and uses a high-resolution touchscreen to display the machine tool's operating status, inspection data, and other information in real time, providing operators with an intuitive human-machine interface for easy understanding of the machine tool's operation. The alarm module consists of an LED light group, a voice alarm, and a buzzer alarm, all three of which are electrically connected to the SoC control chip. The LED light group is connected to the PWM port of the SoC control chip. When the device detects an abnormality in the machine tool's operation, the SoC control chip will trigger the alarm module, promptly alerting the operator through multiple methods such as flashing LED lights, voice alarm announcements, and buzzer alarm sounds, enabling rapid response and ensuring the safe operation of the machine tool.

[0021] The working principle of this device is as follows: The laser displacement sensor in the detection module emits a modulated laser beam onto the surface of the workpiece or tool being measured. Using the triangulation principle, the reflected light signal is converted into an electrical signal, which is then pre-processed by a signal conditioning circuit and transmitted to the SoC control chip. A three-axis MEMS vibration sensor array is deployed on the spindle box bearing housing and the side of the machine tool bed rail, transmitting the detected vibration electrical signals to the SoC control chip. An infrared thermometer acquires the temperature change signal of the detection area and sends it to the SoC control chip. The SoC control chip, based on an ARM Cortex-A53 core, processes the displacement, vibration, and temperature data in parallel. Real-time data interaction is achieved through a dual-mode communication module. When the vibration amplitude, temperature value, or displacement measurement value deviates from the machining process parameters, an alarm signal is sent to the alarm module, triggering an alarm mode. Three levels of early warning are provided through LED lights (red, yellow, and green indicators), a voice alarm (supporting multi-language broadcasting), and a buzzer alarm.

[0022] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model. For those skilled in the art, various modifications and variations can be made to the embodiments of the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An online inspection device for CNC machine tools, characterized in that, include: The module includes a sensor detection module, a data processing module, and a dual-mode communication module. The sensing and detection module includes a laser displacement sensor, a vibration sensor group, and an infrared thermometer, which are installed on the machine tool. The data processing module is connected to the sensing and detection module via an industrial bus. The data processing module includes a SoC control chip and a storage unit, and the storage unit is electrically connected to the SoC control chip. The dual-mode communication module includes wired and wireless dual-channel transmission interfaces, and the data processing module is electrically connected to the dual-mode communication module.

2. The online inspection device for CNC machine tools as described in claim 1, characterized in that, The laser displacement sensor is mounted on the machine tool via a multi-degree-of-freedom adjustable bracket, and the infrared thermometer is mounted on the machine tool via a strong magnet adsorption mechanism. A shock-absorbing structure connects the strong magnet and the infrared thermometer.

3. The online inspection device for CNC machine tools as described in claim 2, characterized in that, The multi-degree-of-freedom adjustable bracket includes a pitch angle adjustment mechanism and an axial telescopic rod. The pitch angle adjustment mechanism adopts a worm gear transmission. The shock absorption structure includes a support plate, a disc spring, a hydraulic damper, and a silicone buffer layer. One end of the disc spring is fixedly mounted on the support plate, and the other end of the disc spring is connected to the hydraulic damper. The hydraulic damper is provided with a silicone buffer layer.

4. The online inspection device for CNC machine tools as described in claim 1, characterized in that, The vibration sensor group adopts a triaxial MEMS sensor. The vibration sensor group includes two vibration sensors. One vibration sensor is fixed to the spindle box bearing seat by a threaded connection, and the other vibration sensor is fixed to the side of the machine tool bed track by a threaded connection.

5. The online inspection device for CNC machine tools as described in claim 1, characterized in that, The laser displacement sensor is electrically connected to the SoC control chip through a signal conditioning circuit, and the vibration sensor group and the infrared thermometer are both electrically connected to the SoC control chip through a serial port.

6. The online inspection device for CNC machine tools as described in claim 1, characterized in that, It also includes a display and an alarm module. The display is electrically connected to the SoC control chip. The alarm module includes an LED light group, a voice alarm, and a buzzer alarm. The LED light group, the voice alarm, and the buzzer alarm are all electrically connected to the SoC control chip.

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