CNC Machine Tool Fault Diagnosis Database via Simulation Modeling
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Solution Overview
Problem
Current fault diagnosis methods for CNC machine tools rely on historical records and expert experience, struggling to provide comprehensive and accurate fault diagnosis due to the complex and irregular nature of faults in these systems.
Innovation Solution
A method and apparatus for generating a fault diagnosis database by simulating various fault conditions in a CNC machine tool, recording fault phenomena, and establishing associations between these phenomena and possible faults, resulting in a comprehensive fault diagnosis database that enhances diagnostic accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fault diagnosis relies on historical fault records and expert experience, then the method is simple to implement, but the coverage of fault diagnosis information is insufficient and accuracy is poor
Solution Approach 1:
The patent applies preliminary action by pre-generating comprehensive fault diagnosis information through simulation before actual faults occur. The system pre-establishes a database containing fault conditions, phenomena, and causal relationships through virtual simulation, so that when real faults occur, the system can quickly match and diagnose without needing complex real-time analysis. This resolves the contradiction by preparing diagnostic data in advance, improving accuracy while keeping the actual diagnosis process simple.
Solution Approach 2:
The patent uses copying by creating a virtual simulation model that replicates the CNC machine tool system. This simulation model copies the structure, components, and operational characteristics of the actual system, allowing comprehensive fault scenario generation without risking the real equipment. The copied virtual environment enables exhaustive fault data collection that would be impractical to obtain from actual machines, thereby improving diagnostic accuracy without proportionally increasing physical system complexity.
2Reliability
If comprehensive fault simulation is performed to cover all fault conditions, then the fault diagnosis information becomes comprehensive and accurate, but the time and resources required for database generation increase significantly
Solution Approach 1:
The patent applies segmentation by dividing the fault diagnosis database generation into distinct modular components: fault condition setting modules, simulation execution modules, phenomenon recording modules, and association establishment modules. Each module handles a specific aspect of fault simulation independently. This segmentation allows parallel processing of different fault scenarios and enables the system to manage comprehensive simulation tasks efficiently, reducing overall generation time while maintaining completeness.
Solution Approach 2:
The system performs preliminary action by pre-generating and storing fault diagnosis information in a structured database before actual diagnostic needs arise. The simulation results, fault phenomena, and causal relationships are computed and organized in advance, creating a ready-to-use knowledge base. This eliminates the need for time-consuming real-time analysis when faults occur, achieving both high reliability and fast response.
3Loss of information
If the fault diagnosis database includes detailed associations between fault phenomena and causes, then the diagnostic information becomes more comprehensive, but the complexity of managing and navigating the database increases
Solution Approach 1:
The patent introduces an intermediary element: a structured association relationship layer that connects fault phenomena to their causes through standardized intermediate representations. This intermediary structure uses uniform data formats and relationship types to bridge the gap between diverse fault phenomena and underlying causes. The standardized intermediate layer organizes complex associations in a systematic way that maintains information completeness while enabling efficient querying and navigation through the database.
Data Source
AI summary
The present invention related to the technical field of industrial automation, in particular to a method and apparatus for generating a fault diagnosis database of a CNC machine tool, intended to conveniently provide comprehensive fault diagnosis information. The method comprises: setting a fault condition of the CNC machine tool; running a simulation model of the CNC machine tool under each set fault condition to generate fault, and recording a fault phenomenon of the fault; backtracking a possible fault generating each fault phenomenon, to establish an association between the fault phenomenon and a possible fault generating the fault phenomenon; generating a fault diagnosis database of the CNC machine tool according to the association established. Due to the fact that what is being run is a simulation model of the CNC machine tool, various fault conditions can be conveniently set. The fault diagnosis database established by the method has the advantage of comprehensive coverage of fault situations and abundant fault diagnosis information. The result of performing fault diagnosis on the basis of such a fault diagnosis database is more accurate.