Impact Analysis Device

Abstract

To provide an impact analyzer that can analyze a continuous impact on an impact analyzer.SOLUTION: An impact analyzer 1 includes: measured value acquisition means 11 for acquiring a measured value that changes according to an impact applied on an impact device at predetermined intervals; time-series data generation means 12 for generating time-series data showing in waveform the change over time of a plurality of measured values continuously acquired at predetermined intervals; and amplitude spectrum generation means 13 for generating an amplitude spectrum showing the accumulated value of the amplitude for each frequency on the basis of the time-series data.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a striking analysis device, and more particularly to a striking analysis device for analyzing the striking of a striking device.

Background Art

[0002] Conventionally, a striking device performs strikes on an object at, for example, a design value of 1800 to 3000 vpm. When such a striking device is continuously used, the number of strikes may decrease from the design value due to wear of components, etc. If it has decreased, repairs, etc. are required to exhibit predetermined performance. Therefore, in a striking device, it is necessary to analyze whether proper strikes are being performed.

[0003] As a device for determining the strike of such a striking device, a striking force determination device has been proposed that determines the striking force of a breaker by measuring the pressure when the hydraulic pressure generated each time the breaker strikes is accumulated in an accumulator via a check valve and the accumulated hydraulic pressure becomes saturated (see Patent Document 1).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, a striking device continuously strikes an object. However, according to the striking force determination device of Patent Document 1, although the striking force of a breaker at a certain point in time can be determined by measuring the pressure when the accumulated hydraulic pressure becomes saturated, in a striking device that continuously strikes, continuous strikes cannot be analyzed.

[0006] An object of the present invention is to provide a strike analysis device in a striking device that can analyze continuous strikes.

Means for Solving the Problems

[0007] (1) A strike analysis device for analyzing strikes of a striking device, comprising: measurement value acquisition means for acquiring measurement values that vary due to strikes in the striking device at a predetermined interval; time series data generation means for generating time series data showing fluctuations in time series of a plurality of the measurement values continuously acquired at the predetermined interval in the form of a waveform; amplitude spectrum generation means for generating an amplitude spectrum showing the cumulative value of amplitudes for each frequency based on the time series data.

[0008] According to the configuration of (1) of the strike analysis device of the present invention, the strike analysis device includes measurement value acquisition means, time series data generation means, and amplitude spectrum generation means, and analyzes strikes of the striking device. The measurement value acquisition means acquires measurement values that vary due to strikes in the striking device at a predetermined interval. The time series data generation means generates time series data showing fluctuations in time series of a plurality of measurement values continuously acquired at a predetermined interval in the form of a waveform. The amplitude spectrum generation means generates an amplitude spectrum showing the cumulative value of amplitudes for each frequency based on the time series data.

[0009] In this way, measurement values (for example, pressure values due to strikes, measured values of striking forces, etc.) that vary due to strikes in the striking device are acquired at a predetermined interval (for example, 5 ms, etc.). Next, time series data showing fluctuations in time series of a plurality of measurement values continuously acquired at a predetermined interval is generated in the form of a waveform. Then, an amplitude spectrum showing the cumulative value of amplitudes for each frequency is generated based on the time series data shown in this waveform.

[0010] Here, in the striking device, when a strike is performed, vibrations and the like generated by this strike remain in the striking device. In a state where such vibrations and the like remain, the next strike is performed, resulting in even more complex vibrations and the like, and these complex vibrations and the like appear in the measured values. Therefore, even if the measured values that vary due to the strike are continuously acquired at predetermined intervals and converted into time-series data showing the time-series variations in waveform, waves with various amplitudes are measured at various frequencies respectively, and it is difficult to determine which wave was generated by an effective strike based on the acquired measured values as they are.

[0011] According to the present invention, based on the time-series data, an amplitude spectrum showing the cumulative value of the amplitude for each frequency is generated, so that the frequency with the largest cumulative value of the amplitude becomes clear. The frequency with the largest cumulative value of the amplitude can be presumed to be the period of the effective strike. For example, if the difference between the frequency with the largest cumulative value of the amplitude in a properly maintained striking device and that at the time of measurement is large, it becomes possible to determine that the striking device at the time of measurement is not performing strikes properly.

[0012] Therefore, it is possible to provide a strike analysis device that can analyze continuous strikes in a striking device.

[0013] (2) The time-series data generation means generates the time-series data using the corrected measured value obtained by subtracting the average value of the measured values acquired by the measured value acquisition means from the measured values, in the strike analysis device according to (1).

[0014] Thereby, in the time-series data, it becomes possible to show the measured values as positive values (values larger than the average value) and negative values (values smaller than the average value), facilitating the analysis of the changes in the measured values in waveform.

[0015] (3) The strike analysis device according to (1) or (2) further includes an effective strike count calculation means for calculating the effective strike count per predetermined time of the striking device by multiplying a predetermined value by the frequency with the highest cumulative value.

[0016] As a result, in the amplitude spectrum, by comparing the effective number of impacts calculated from the frequency with the highest cumulative value with, for example, the designed number of impacts (for example, in the case of an impact device driven by fluid pressure fluctuations, the number of pressure fluctuations, etc.), it becomes possible to determine whether an appropriate number of impacts is maintained in the impact device during measurement.

[0017] (4) Storage means for storing the amplitude spectrum generated by the amplitude spectrum generation means; The impact analysis device according to any one of (1) to (3), further comprising display control means for controlling to display the amplitude spectrum generated by the amplitude spectrum generation means on a display means. The storage means stores a plurality of the amplitude spectra generated at different timings respectively; The display control means performs control to display a plurality of the amplitude spectra generated at different timings superimposed.

[0018] In this way, by superimposing and displaying a plurality of amplitude spectra generated at different timings, for example, by superimposing and displaying the amplitude spectrum immediately after maintenance and the amplitude spectrum after a predetermined inspection period (for example, after one year, etc.), changes in the cumulative value of the amplitude at the overall frequency can be confirmed at a glance. Therefore, analysis of continuous impacts in the impact device becomes easier.

Advantages of the Invention

[0019] According to the present invention, it is possible to provide an impact analysis device capable of analyzing continuous impacts in an impact device.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2

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Figure 5

Figure 6

Mode for Carrying Out the Invention

[0021] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following description, the same components are denoted by the same reference numerals, and the description thereof will be omitted or simplified. FIG. 1 is a diagram for explaining a state where a hitting analysis device according to an embodiment of the present invention is attached to a hitting device.

[0022] (Overall Configuration) The hitting analysis device 1 includes a detection unit 5 that detects the hitting of the hitting device 100, a control unit 10 that analyzes the hitting of the hitting device 100, and a display means 20 that displays the analysis result of the control unit 10, and analyzes the hitting of the hitting device 100.

[0023] Here, the hitting device 100 usually repeats hitting at 1800 to 3000 vpm. When measuring the hitting force, not all of them are constant, and they repeat increasing and decreasing. However, the increase and decrease of the hitting force occur periodically and regularity is recognized. Therefore, the hitting analysis device 1 acquires a measured value that varies due to the hitting in the hitting device 100, and based on this measured value, analyzes the tendency of the variation of the measured value, thereby enabling the analysis of the hitting of the hitting device.

[0024] The impact device 100 of the present embodiment continuously impacts a cast product (not shown) set on the frame 110 with the impact portion 120 (in the example shown in FIG. 1, as the piston (not shown) inside the impact device 100 moves up and down, the piston collides with the impact portion 120 during the downward movement). As a result, the tip of the impact portion 120 continuously applies an impact load to the cast product, removing the core sand of the cast product. In the example shown in FIG. 1, the detection unit 5 of the impact analysis device 1 is arranged at the position where the cast product is installed (the position where the impact is performed by the impact portion 120).

[0025] In the example shown in FIG. 1, the detection unit 5 includes a cylinder 51, a piston 52, a replaceable member 53, and a detection means 54. The cylinder 51 is filled with an incompressible fluid inside. The piston 52 is slidably attached to the cylinder 51, moves in the slidable direction by the impact portion 120 of the impact device 100, and transmits the pressure caused by the impact of the impact portion 120 of the impact device 100 to the inside of the cylinder 51. The replaceable member 53 is detachably attached to the portion of the piston 52 that is impacted by the impact portion 120 and is directly impacted by the impact portion 120. The replaceable member 53 can be replaced when it is deformed or worn by the impact. The detection means 54 is fluid-connected to the inside of the cylinder 51 and is composed of a pressure sensor that constantly detects the pressure inside the cylinder 51.

[0026] With such a configuration, when the impact device 100 performs an impact, the impact portion 120 impacts (moves downward) the replaceable member 53 of the detection unit 5. The impact force caused by this impact is transmitted to the piston 52, increasing the pressure of the incompressible fluid inside the cylinder 51. Then, when the piston (not shown) inside the impact device 100 rises and no impact load is applied to the impact portion 120, the pressure applied to the piston 52 of the detection unit 5 is released, and the pressure of the incompressible fluid inside the cylinder 51 decreases.

[0027] The detection means 54 constantly detects such continuous pressure fluctuations of the incompressible fluid in the continuous impact by the impact device 100.

[0028] In the example shown in FIG. 1, the detection unit 5 is configured to measure the value that varies due to the impact in the impact device 100 using a pressure sensor. However, the present invention is not limited to this. As long as the value that varies due to the impact by the impact unit 120 of the impact device 100 can be measured, for example, it can be configured to measure the impact force of the impact device 100 with a load cell (strain gauge), or to measure the state of the portion struck by the impact device 100 with an acceleration sensor, etc., and can be any configuration.

[0029] (Functional configuration) FIG. 2 is a diagram for explaining the functional configuration of the impact analysis device 1 according to an embodiment of the present invention. The control unit 10 includes a measurement value acquisition means 11, a time-series data generation means 12, an amplitude spectrum generation means 13, an effective impact count calculation means 14, a display control means 15, and a storage means 50, and the detection means 54 and the display means 20 of the detection unit 5 are connected.

[0030] The measurement value acquisition means 11 is connected to the detection means 54 of the detection unit 5 and acquires the measurement values that vary due to the impact in the impact device 100 at a predetermined interval. Specifically, the measurement value acquisition means 11 converts the value, which is an analog signal detected by the detection means 54, into a digital signal to acquire the measurement value and stores it in the storage means 50.

[0031] The predetermined interval at which the measurement value acquisition means 11 acquires the measurement value may be a preset interval, or may be an interval set based on the number of impacts set in the impact device 100, and it is desirable that the interval be less than or equal to the impact interval of the impact device 100. For example, when the number of impacts of the impact device 100 is set to 3000 vpm, the predetermined interval at which the measurement value acquisition means 11 acquires the measurement value is desirably an interval of measuring 50 (3000 vpm / 60) times or more per second, that is, 20 ms (1000 ms / 50 times) or less.

[0032] The time-series data generation means 12 generates time-series data that shows the fluctuations of a time series of a plurality of measurement values continuously acquired at a predetermined interval in the form of a waveform. Specifically, the time-series data generation means 12 reads out a predetermined number of the plurality of measurement values continuously acquired at a predetermined interval stored in the storage means 50, generates time-series data that shows the fluctuations of the time series of the read measurement values in the form of a waveform, and stores it in the storage means 50.

[0033] Here, since the amplitude spectrum generation means 13 generates an amplitude spectrum based on the time-series data generated by the time-series data generation means 12 by known fast Fourier transform, it is desirable that the predetermined number of measurement values read out by the time-series data generation means 12 be a power of 2 (for example, 256, 512, etc.).

[0034] Also, the time-series data generation means 12 generates time-series data using corrected measurement values obtained by subtracting the average value of the measurement values acquired by the measurement value acquisition means 11 from the measurement values. Thereby, the DC component of the measurement values acquired by the measurement value acquisition means 11 is removed, and it becomes possible to analyze the frequency of the fluctuations of the continuously acquired measurement values.

[0035] Also, the time-series data generation means 12 generates Hanning-processed data obtained by multiplying the time-series data by a known Hanning function, and stores it in the storage means 50. Thereby, the continuity of the waveform is improved, and the accuracy of data analysis is improved.

[0036] The amplitude spectrum generation means 13 generates an amplitude spectrum that shows the cumulative value of the amplitudes for each frequency based on the time-series data generated by the time-series data generation means 12. Specifically, the amplitude spectrum generation means 13 processes the time-series data or the Hanning-processed data generated by the time-series data generation means 12 by known fast Fourier transform to generate an amplitude spectrum that shows the cumulative value of the amplitudes for each frequency, and stores it in the storage means 50.

[0037] The effective strike count calculation means 14 calculates the effective strike count per predetermined time of the striking device by multiplying a predetermined value by the frequency with the highest cumulative amplitude value. Specifically, the effective strike count calculation means 14 refers to the amplitude spectrum generated by the amplitude spectrum generation means 13, identifies the frequency with the highest cumulative value, and multiplies the identified frequency by 60, which is the conversion rate from frequency (Hz) to strike count (vpm), to calculate the effective strike count. For example, when the frequency with the highest cumulative value is 35 Hz, the effective strike count calculation means 14 calculates 2100 vpm as the effective strike count.

[0038] The display control means 15 reads out the time-series data generated by the time-series data generation means 12, the amplitude spectrum converted by the amplitude spectrum generation means 13, and the effective strike count calculated by the effective strike count calculation means 14 from the storage means 50, and performs control to display them on the display means 20 (for example, a display or the like). In addition, the display control means 15 performs control to superimpose and display a plurality of amplitude spectra stored in the storage means 50 and generated by the amplitude spectrum generation means 13 at different timings.

[0039] The storage means 50 temporarily stores the measurement values acquired by the measurement value acquisition means 11, stores the time-series data generated by the time-series data generation means 12, the amplitude spectrum generated by the amplitude spectrum generation means 13, and the effective strike count calculated by the effective strike count calculation means 14. In addition, the storage means 50 stores the amplitude spectra generated by the amplitude spectrum generation means 13 at different timings, respectively.

[0040] The functional configuration of the above control unit 10 is merely an example, and one functional block (database and functional processing unit) may be divided, or a plurality of functional blocks may be combined into one functional block. Each functional processing unit is realized by a computer program (for example, core software or an application that causes the CPU to execute the above various processes) stored in a storage device (storage means 50) such as a CPU (Central Processing Unit) built into the device, a ROM (Read Only Memory), a flash memory, an SSD (Solid State Drive), or a hard disk, which is read out by the CPU and executed by the CPU. That is, each functional processing unit reads and writes necessary data such as tables from a database (DB; Data Base) stored in the storage device or a storage area in the memory by this computer program, and in some cases, controls related hardware (for example, input / output devices, display devices, communication interface devices). Further, the database (DB) in the embodiment of the present invention may be a commercial database, but also means a mere collection of tables or files, and the internal structure of the database itself is not limited.

[0041] (Processing Flow) FIG. 3 is a diagram showing a hitting analysis processing flow executed by the hitting analysis device according to an embodiment of the present invention. In the processing flow diagram (flowchart) of FIG. 3, the processing order of each step may be changed as long as the input-output relationship of each step is not impaired.

[0042] In step S1, the measurement value acquisition means 11 acquires measurement values that vary due to hitting in the hitting device 100 at a predetermined interval.

[0043] In step S2, the time-series data generation means 12 generates time-series data showing the time-series variation of a plurality of measurement values continuously acquired by the measurement value acquisition means 11 at a predetermined interval in step S1 in the form of a waveform, and stores it in the storage means 50.

[0044] In step S3, the amplitude spectrum generation means 13 generates an amplitude spectrum indicating the cumulative value of the amplitude for each frequency based on the time-series data generated by the time-series data generation means 12 in step S2, and stores it in the storage means 50.

[0045] In step S4, the effective strike count calculation means 14 calculates the effective strike count per predetermined time of the striking device by multiplying a predetermined value by the frequency at which the cumulative value is the highest with reference to the amplitude spectrum generated by the amplitude spectrum generation means 13 in step S3.

[0046] In step S5, the display control means 15 reads out from the storage means 50 the time-series data generated by the time-series data generation means 12 in step S2 and the amplitude spectrum converted by the amplitude spectrum generation means 13 in step S3, and performs control to display them on the display means 20 (for example, a display or the like).

[0047] FIG. 4 is a diagram showing an example of displaying time-series data according to an embodiment of the present invention. In the example of displaying time-series data, the number (order) of measurement values continuously acquired at predetermined intervals by the measurement value acquisition means 11 is set on the horizontal axis, and the waveform in which the magnitude of each measurement value is set is shown on the vertical axis.

[0048] The display control means 15 may, for example, as shown in FIG. 4, display the time-series data and the Hanning processed data obtained by multiplying the time-series data by the Hanning function in different modes (for example, modes with different brightness, color, thickness, line type, etc.) superimposed on each other.

[0049] FIG. 5 is a diagram showing an example of displaying an amplitude spectrum according to an embodiment of the present invention. In the example of displaying the amplitude spectrum, the frequency (Hz) is set on the horizontal axis, and the cumulative value of the amplitude for each frequency is shown in a graph form on the vertical axis.

[0050] The display control means 15 may, for example, as shown in FIG. 5, superimpose and display a plurality of amplitude spectra converted at different timings in different manners (for example, manners in which luminance, color, thickness, line type, etc. are different).

[0051] (Modification example) FIG. 6 is a diagram for explaining a state in which a strike analysis device according to a modification example of an embodiment of the present invention is attached to a striking device.

[0052] The strike analysis device 1A according to the modification example differs from the strike analysis device 1 according to the present embodiment in the configuration of the detection unit 5A. The detection unit 5A is a tubular body connected to a circuit of striking air for driving the striking unit 120 of the striking device 100, and includes a connection portion 51A filled with striking air and having the same internal pressure as that in the circuit of striking air, and a detection means 54.

[0053] The detection means 54 constantly detects continuous pressure fluctuations of the striking air in continuous strikes by the striking device 100.

[0054] The striking unit 120 of the striking device 100 supplies striking air inside the striking device 100 to move a piston (not shown) inside up and down. When the piston collides with the striking unit 120 during the downward movement, the tip of the striking unit 120 continuously applies an impact load to the casting product. This piston has different areas on the ascending side and the descending side. By widening the area on the ascending side, when equal pressures are generated on both sides, the piston is raised by the difference in thrust. Next, in order to lower this, the supply of striking air to the ascending side is stopped at a certain position by an internal mechanism and exhausted. As a result, the thrust on the descending side wins and the piston descends. When the descending end (the position where it collides with the striking unit 120) is reached, the supply of striking air is performed again, and the piston repeatedly moves up and down. That is, when the piston rises, the striking air on the ascending side that has been exhausted flows in, so a temporary pressure drop occurs every time a strike is made.

[0055] According to the impact analysis device 1A according to the modification example, by analyzing such pressure fluctuations, it becomes possible to analyze continuous impacts in the impact device 100.

[0056] Also, according to the impact analysis device 1A according to the modification example, while the impact device 100 is being normally used, continuous impacts in the impact device 100 can be analyzed. Therefore, even in an environment where it is difficult to stop facilities such as factory lines, or in an automated environment, the impacts of the impact device 100 can be analyzed.

[0057] As described above, according to the impact analysis device 1 according to the present embodiment, the following operational effects are achieved. According to the impact analysis device 1, measurement values (for example, pressure values due to impacts, measured values of impact forces, etc.) that vary due to impacts in the impact device 100 are acquired at predetermined intervals (for example, 5 ms, etc.). Next, time-series data is generated that shows, in waveform, the variations in the time series of a plurality of measurement values continuously acquired at predetermined intervals. Then, based on the time-series data shown in this waveform, an amplitude spectrum showing the cumulative value of the amplitudes for each frequency is generated. Thereby, since an amplitude spectrum showing the cumulative value of the amplitudes for each frequency is generated based on the time-series data, the frequency with the largest cumulative value of the amplitudes becomes clear. The frequency with the largest cumulative value of the amplitudes can be inferred as the period of the effective impact. For example, if the difference between the frequency with the largest cumulative value of the amplitudes in the properly maintained impact device 100 and that at the time of measurement is large, it becomes possible to determine that the impact device 100 at the time of measurement is not performing impacts properly. Therefore, it is possible to provide an impact analysis device that can analyze continuous impacts in the impact device 100.

[0058] Further, according to the impact analysis device 1, the time-series data generation means 12 generates time-series data using the corrected measurement value obtained by subtracting the average value of the measurement values acquired by the measurement value acquisition means 11 from the measurement values. Therefore, in the time-series data, the measurement values can be shown as positive values (values larger than the average value) and negative values (values smaller than the average value), making it easier to analyze the change in the measurement values in the form of a waveform.

[0059] Also, according to the impact analysis device 1, by comparing the effective number of impacts calculated from the frequency with the highest cumulative value in the amplitude spectrum with, for example, the designed number of impacts (e.g., in the case of the impact device 100 driven by the pressure fluctuation of a fluid, the number of pressure fluctuations, etc.), it becomes possible to determine whether an appropriate number of impacts is being maintained in the impact device 100 during measurement.

[0060] Further, according to the impact analysis device 1, by overlapping and displaying a plurality of amplitude spectra generated at different timings, for example, by overlapping and displaying the amplitude spectrum immediately after maintenance and the amplitude spectrum after a predetermined inspection period (e.g., after one year, etc.), it is possible to comprehensively confirm the change in the cumulative value of the amplitude at the overall frequency. Therefore, the analysis of continuous impacts in the impact device 100 becomes easier.

[0061] Note that the present invention is not limited to the above-described embodiment, and modifications, improvements, etc. within the scope that can achieve the object of the present invention are included in the present invention.

Explanation of Reference Numerals

[0062] 1, 1A Impact analysis device 5, 5A Detection unit 10 Control unit 11 Measurement value acquisition means 12 Time-series data generation means 13 Amplitude spectrum generation means 14 Effective number of impacts calculation means 15 Display control means 20 Display means 50 Storage means 51 Cylinder 51A Connection part 52 Piston 53 Replaceable member 54 Detection means 100 Impact device 110 Frame 120 Impact part

Claims

1. A blow analysis device for analyzing the blow of a blow device that continuously applies an impact load to a cast product by a blow part to remove the core sand of the cast product, measurement value acquisition means for acquiring a measurement value that varies by continuous blows in the blow device at a predetermined interval according to the number of blows in the blow device; time series data generation means for generating time series data showing the variation of a time series of a plurality of the measurement values continuously acquired at the predetermined interval in a waveform; amplitude spectrum generation means for generating an amplitude spectrum showing the cumulative value of the amplitude for each frequency based on the time series data; effective blow count calculation means for calculating the effective blow count per predetermined time of the blow device by multiplying the frequency with the highest cumulative value by the conversion rate to the number of blows, the blow analysis device comprising the same.

2. The blow analysis device according to claim 1, wherein the time series data generation means generates the time series data using a corrected measurement value obtained by subtracting the average value of the measurement values acquired by the measurement value acquisition means from the measurement values.

3. storage means for storing the amplitude spectrum generated by the amplitude spectrum generation means; further comprising display control means for performing control to display the amplitude spectrum generated by the amplitude spectrum generation means on a display means, the storage means stores a plurality of the amplitude spectra generated at different timings respectively, The blow analysis device according to claim 1 or 2, wherein the display control means performs control to display a plurality of the amplitude spectra generated at different timings superimposed.

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