CN113103067B - Cutter machining frequency monitoring system and detection method based on low-power-consumption design - Google Patents

Abstract

The invention discloses a cutter processing frequency monitoring system and a monitoring method based on low power consumption design, wherein the monitoring system and the monitoring method can monitor vibration information of a cutter in three axial directions in real time through a triaxial acceleration sensor, and then the processing frequency of the cutter is obtained by analyzing and calculating the acquired vibration signal and time domain information corresponding to the vibration signal; by combining the vibration information and the time domain information for simultaneous analysis, the accuracy of the monitoring result can be improved. In addition, the invention can effectively manage the processing operation efficiency of field workers and effectively supervise the quality of the cutter provided by a cutter production enterprise. In addition, the invention can reduce the volume of the storage battery and further reduce the volume of the whole monitoring module by enabling the three-axis acceleration sensor and the microprocessor to work in a low-power-consumption mode for a long time, so that the monitoring module can be installed on the cutter.

Description

Tool processing frequency monitoring system and detection method based on low power consumption design

technical field

The invention relates to a tool processing times monitoring system and detection method based on low power consumption design.

Background technique

Tool condition monitoring of CNC machine tool is the key technology of advanced manufacturing system and an important link in the machining process. An effective monitoring system for the tool status of CNC machine tools has important practical significance for improving production efficiency, reducing production costs, and improving product quality. Therefore, the research on the state monitoring of CNC machine tools is particularly important.

Tool processing frequency monitoring is an important link in the management process of automated machinery manufacturing. Monitoring the processing frequency can not only effectively manage the processing efficiency of on-site workers, but also effectively supervise the quality of tools provided by tool manufacturers. However, the tool processing environment is harsh and changeable, and the state of the tool includes: daily storage, transportation, tool loading, tool changing, processing operations, etc. However, there is currently no related technology for automatic monitoring of tool processing times, and the current CNC machining center does not provide power to the tool. At the same time, the tool body is limited in the space available for modification. Therefore, the installation position of the battery system is limited. Ultimately, the entire System power is limited. To sum up, in the face of a complex processing environment, it is difficult to monitor the tool in real time according to the conventional method, limited by the battery capacity.

Contents of the invention

The purpose of the present invention is to provide a tool processing frequency monitoring system and detection method based on low power consumption design, which can automatically monitor the tool processing frequency.

In order to solve the above-mentioned technical problems, the present invention provides a tool processing times monitoring system based on low power consumption design, the monitoring system includes a measurement module, and the measurement module includes a three-axis acceleration sensor and a microprocessor;

The triaxial acceleration sensor is used to collect tool vibration information in real time;

The microprocessor is used to obtain the vibration information of the tool, and then calculate the machining times of the tool according to the characteristics of the vibration signal during tool processing, and then combine the real-time tool vibration information and the time domain signal corresponding to the tool vibration information.

Further, the microprocessor specifically calculates the machining times of the tool by the following method:

When the microprocessor acquires the tool vibration information signal corresponding to the characteristics of the vibration signal during tool processing, start timing until the microprocessor obtains a tool vibration signal with different characteristics from the vibration signal during tool processing, then stop timing;

Then calculate whether the timing duration of the above steps matches the processing time. If so, it is judged that a tool processing is completed, and the number is counted; if not, it is not counted;

Repeat the above steps until the processing is completed.

Further, the monitoring system also includes a lithium battery for powering the measurement module.

Further, the triaxial acceleration sensor and the microprocessor work in a low power consumption mode;

Initially, the three-axis acceleration sensor performs low-frequency signal sampling in a state of low power consumption. When the three-axis acceleration sensor collects the tool vibration information signal corresponding to the vibration signal characteristics of the tool during machining, an interrupt signal is generated and the microprocessor is woken up. After waking up, the microprocessor controls the three-axis acceleration sensor to enter the interrupt mode, and then the microprocessor and the three-axis acceleration sensor re-enter the low power consumption mode; until the characteristics of the vibration signal collected by the three-axis acceleration sensor are different from those during tool processing When the vibration signal of the cutting tool is generated, the interrupt signal is generated again and the microprocessor is woken up, and the timing is stopped.

Further, according to the corresponding time domain signals of different working conditions, the optimal features that can be discretized are selected.

Further, the detection system also includes a server communicated with the microprocessor, and an alarm unit and a display unit respectively connected with the server.

Further, the detection system also includes a mobile terminal communicatively connected to the server.

In addition, the present invention also provides a method for monitoring tool processing times using the above-mentioned tool processing frequency monitoring system based on low power consumption design. The monitoring method includes the following steps:

S1: Real-time collection of tool vibration information;

S2: Obtain the tool vibration information, and then calculate the number of times the tool is processed according to the characteristics of the vibration signal during tool machining, combined with the real-time tool vibration information and the time domain signal corresponding to the tool vibration information.

Further, the step S2 specifically includes:

S21: When the tool vibration information signal corresponding to the vibration signal characteristics during tool processing is obtained, start timing, and stop timing until the microprocessor obtains a tool vibration signal with different vibration signal characteristics during tool processing;

S22: Then calculate whether the timing duration of the above steps matches the processing time, if yes, it is judged that one tool processing is completed, and the number is counted; if not, it is not counted;

S23: Repeat the above steps until the processing is completed.

The beneficial effects of the present invention are: the vibration information of the tool in three axial directions can be monitored in real time through the three-axis acceleration sensor, and then the machining times of the tool can be obtained by analyzing and calculating the collected vibration signal and its corresponding time domain information ; By combining vibration information and time domain information for simultaneous analysis, the accuracy of monitoring results can be improved. The system can also effectively manage the processing efficiency of on-site workers, and can effectively supervise the quality of tools provided by tool manufacturers.

Description of drawings

The accompanying drawings described here are used to provide a further understanding of the application and constitute a part of the application. In these drawings, the same reference numerals are used to indicate the same or similar parts. The illustrative embodiments of the application and their descriptions are used The purpose of explaining this application does not constitute an improper limitation of this application. In the attached picture:

Fig. 1 is the structural block diagram of this monitoring system;

Detailed ways

As shown in Figure 1, based on the low-power consumption design tool processing times monitoring system, the monitoring system includes a measurement module, and the measurement module includes a three-axis acceleration sensor and a microprocessor;

The triaxial acceleration sensor is used to collect tool vibration information in real time;

The microprocessor is used to obtain the vibration information of the tool, and then calculate the machining times of the tool according to the characteristics of the vibration signal during tool processing, and then combine the real-time tool vibration information and the time domain signal corresponding to the tool vibration information.

The present invention can monitor the vibration information of the tool in three axial directions in real time through the three-axis acceleration sensor, and then obtain the processing times of the tool by analyzing and calculating the collected vibration signal and its corresponding time domain information; by combining the vibration information Simultaneous analysis with time domain information can improve the accuracy of monitoring results.

According to an embodiment of the present application, the microprocessor specifically calculates the number of machining times of the tool by the following method:

When the microprocessor acquires the tool vibration information signal corresponding to the characteristics of the vibration signal during tool processing, start timing until the microprocessor obtains a tool vibration signal with different characteristics from the vibration signal during tool processing, then stop timing;

Then calculate whether the timing duration of the above steps matches the processing time. If so, it is judged that a tool processing is completed, and the number is counted; if not, it is not counted;

Repeat the above steps until the processing is completed.

According to an embodiment of the present application, the monitoring system further includes a lithium battery for powering the measurement module. The convenience of monitoring collaboration can be improved by using lithium battery power supply.

According to an embodiment of the present application, the triaxial acceleration sensor and the microprocessor work in a low power consumption mode;

Initially, the three-axis acceleration sensor performs low-frequency signal sampling in a state of low power consumption. When the three-axis acceleration sensor collects the tool vibration information signal corresponding to the vibration signal characteristics of the tool during machining, an interrupt signal is generated and the microprocessor is woken up. After waking up, the microprocessor controls the three-axis acceleration sensor to enter the interrupt mode, and then the microprocessor and the three-axis acceleration sensor re-enter the low power consumption mode; until the characteristics of the vibration signal collected by the three-axis acceleration sensor are different from those during tool processing When the vibration signal of the cutting tool is generated, the interrupt signal is generated again and the microprocessor is woken up, and the timing is stopped.

By making the three-axis acceleration sensor and microprocessor work in low power consumption mode for a long time, the volume of the battery can be reduced, so that the total thickness of the lithium battery and the circuit board of the entire monitoring module can be as small as 13mm except for the thickness of the shell. The measuring module is suitable for installation positions with a minimum diameter of 15mm and a minimum depth of 15mm.

According to an embodiment of the present application, according to the corresponding time-domain signals of different working conditions, the optimal features that can be discretized are selected.

According to an embodiment of the present application, the detection system further includes a server communicated with the microprocessor, and an alarm unit and a display unit respectively connected with the server. The server has a built-in background cloud service program, and the data is pushed by onenet. It has the following functions: display of online module information, display of historical data of module processing times, and reminder of module alarm information. Among them, the online module information includes: the manufacturer of the tool installed in the module, the tool model, the material of the tool to be processed, the tool processing speed, the tool processing feed rate, the station where the tool is located, etc. Module alarm information reminders include: monitoring whether the module is in the designated work area information reminders, tool processing times are normal reminders.

According to an embodiment of the present application, the detection system further includes a mobile terminal communicatively connected to the server. Among them, the mobile terminal can choose computer equipment used in mobile according to needs, such as mobile phone, notebook, tablet computer, smart bracelet and so on. There is an APP built into the mobile terminal, and the APP can provide an interactive channel for users to input data and view information. The personnel who use the tool enter information such as the manufacturer of the tool installed in the module, the model of the tool, the material of the tool to be processed, the speed of tool processing, the feed rate of the tool, and the station where the tool is located; the management personnel can view each station Tool processing conditions. In principle, all information from the server can be pushed to the APP.

According to an embodiment of the present application, the microprocessor can adopt esp82xx series or CC32xx series with WIFI function, and can also be easily transplanted to other microprocessors with RF function. The background cloud service program builds a device connection gateway based on the OneNET platform, builds a data processing cloud platform, and can be easily transplanted to other platforms such as Alibaba Cloud.

In addition, the present invention also provides a method for monitoring tool processing times using the above-mentioned tool processing frequency monitoring system based on low power consumption design. The monitoring method includes the following steps:

S1: Real-time collection of tool vibration information;

S2: Obtain the tool vibration information, and then calculate the number of times the tool is processed according to the characteristics of the vibration signal during tool machining, combined with the real-time tool vibration information and the time domain signal corresponding to the tool vibration information.

According to an embodiment of the present application, the step S2 specifically includes:

S21: When the tool vibration information signal corresponding to the vibration signal characteristics during tool processing is obtained, start timing, and stop timing until the microprocessor obtains a tool vibration signal with different characteristics from the vibration signal characteristics during tool processing;

S22: Then calculate whether the timing duration of the above steps matches the processing time, if yes, it is judged that one tool processing is completed, and the number is counted; if not, it is not counted;

S23: Repeat the above steps until the processing is completed.

Finally, it is noted that the above embodiments are only used to illustrate the technical solutions of the present invention without limitation. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be carried out Modifications or equivalent replacements without departing from the spirit and scope of the technical solution of the present invention shall be covered by the claims of the present invention.

Claims (7)

1. A cutter machining frequency monitoring system based on low-power-consumption design is characterized by comprising a measuring module, wherein the measuring module comprises a three-axis acceleration sensor and a microprocessor;

the three-axis acceleration sensor is used for acquiring cutter vibration information in real time;

the microprocessor is used for acquiring the cutter vibration information, and then calculating the machining times of the cutter by combining the real-time cutter vibration information and the time domain signal corresponding to the cutter vibration information according to the characteristics of the vibration signal during cutter machining; the microprocessor calculates the machining times of the cutter by the following method:

when the microprocessor acquires a tool vibration information signal corresponding to the vibration signal characteristic during tool machining, timing is started, and timing is stopped until the microprocessor acquires a tool vibration signal with a vibration signal characteristic different from that during machining;

then calculating whether the timing duration of the steps is matched with the processing time, if so, judging that one-time cutter processing is finished, and counting one time; if not, not counting;

and repeating the steps until the processing is finished.

2. The tool machining frequency monitoring system designed based on low power consumption is characterized by further comprising a lithium battery for supplying power to the measuring module.

3. The system for monitoring the number of times of tool machining based on low power consumption design according to claim 2, wherein the three-axis acceleration sensor and the microprocessor operate in a low power consumption mode;

initially, sampling a low-frequency signal by a triaxial acceleration sensor in a low-power-consumption state, generating an interrupt signal and awakening a microprocessor when the triaxial acceleration sensor acquires a tool vibration information signal corresponding to the vibration signal characteristic during tool machining, controlling the triaxial acceleration sensor to enter an interrupt mode by the awakened microprocessor, and then re-entering the low-power-consumption mode by the microprocessor and the triaxial acceleration sensor; and generating an interrupt signal again and awakening the microprocessor to stop timing until the triaxial acceleration sensor acquires a tool vibration signal with different characteristics from the vibration signal during machining.

4. The system for monitoring the number of times of machining of the cutting tool designed based on low power consumption as claimed in claim 3, wherein the optimum characteristics capable of being discretized are selected according to the corresponding time domain signals of different working conditions.

5. The system for monitoring the machining times of the tool designed based on the low power consumption of claim 1, further comprising a server in communication with the microprocessor, and an alarm unit and a display unit respectively connected to the server.

6. The system for monitoring the number of times of tool machining based on low power consumption design according to claim 5, further comprising a mobile terminal in communication connection with the server.

7. A tool machining number monitoring method for monitoring a tool machining number by using the tool machining number monitoring system designed based on low power consumption according to any one of claims 1 to 6, comprising the steps of:

s1: collecting cutter vibration information in real time;

s2: acquiring the cutter vibration information, and then calculating the machining times of the cutter by combining the real-time cutter vibration information and a time domain signal corresponding to the cutter vibration information according to the characteristics of a vibration signal generated when the cutter is machined;

the step S2 specifically includes:

s21: when a tool vibration information signal corresponding to the vibration signal characteristic during tool machining is obtained, timing is started, and the timing is stopped until the microprocessor obtains a tool vibration signal with a different vibration signal characteristic during tool machining;

s22: then calculating whether the timing duration of the steps is matched with the processing time, if so, judging that one-time cutter processing is finished, and counting one time; if not, not counting;

s23: and repeating the steps until the processing is finished.

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