卧式加工中心远程故障诊断系统开发

发布时间：2018-04-01 20:07

本文选题：加工中心　切入点：故障诊断　出处：《昆明理工大学》2017年硕士论文

【摘要】：自主研发的新型加工中心的可靠性是影响其性能的重要因素,对其可靠性分析是提高加工中心性能的一种重要方法。加工中心的远程故障诊断是可靠性分析的重要内容。为了加工中心的在运行过程中能够安全、稳定地运行,避免重大事故的发生,提高生产效率和机床的利用率,以提高其性能。本文针对加工中心的实际情况,设计开发加工中心旋转部件的故障诊断系统和加工中心数控系统的故障诊断系统。并对加工中心转台进行了有限元寿命分析。实现通信是解决远程故障诊断的基础,首先通过RS-232C接口选择工业以太网实现数控系统与通信设备的通信,利用远程通信设备中的3Gmodem模块与计算机的通信,最后实现数据的传输,获取所需的数据。故障数据是确定所得信号是否为故障的基础。设计加工中心故障诊断系统分为旋转部件的故障诊断系统和数控系统的故障诊断系统两部分。加工中心旋转部件的故障诊断系统是基于振动信号处理,提取故障特征以达到故障诊断的目标。首先对故障振动信号进行处理。采用时域分析主要包括统计特征参量分析和相关函数分析。采用频域分析主要有幅值谱分析、功率谱分析、倒频谱分析和细化谱分析。此外还引入了小波分析方法对加工中心启停时的振动信号进行处理提取故障特征,以便用户故障诊断,利用MATLAB软件设计了诊断系统。通过加工中心转台的模态试验,验证了所建立的有限元模型的准确性。获得对转台固有频率计算值和试验值相关性分析结果,可用于后续对有限元模型进行疲劳分析,得出所设计的转台的寿命达到预期的设计值。加工中心数控系统的故障诊断系统是根据故障案例库对数控系统提供的报警进行故障诊断。故障案例库的建立需要三个方面的内容包括:用户机床自定义故障信息;西门子840D故障报警手册;加工中心的故障状态、故障原因、危害度等的分析结果。对加工中心的故障进行整理后,结合编程软件进行人机交互界面的设计并添加了故障分类统计的功能,对故障预防决策有一定程度参考价值。
[Abstract]:The reliability of the newly developed machining center is an important factor affecting its performance, and the reliability analysis is an important method to improve the performance of the machining center.Remote fault diagnosis of machining center is an important content of reliability analysis.In order to operate the machining center safely and stably, to avoid serious accidents, and to improve the efficiency of production and the utilization rate of machine tools, so as to improve the performance of machining center.According to the actual situation of machining center, the fault diagnosis system of rotating parts of machining center and the fault diagnosis system of NC system of machining center are designed and developed in this paper.The finite element life analysis of machining center turntable is carried out.Communication is the foundation of remote fault diagnosis. Firstly, the communication between NC system and communication equipment is realized by RS-232C interface, the communication between CNC system and communication equipment is realized by using 3Gmodem module of remote communication equipment, and finally the data transmission is realized.Gets the required data.Fault data is the basis for determining whether the signal is a fault.The fault diagnosis system of machining center is divided into two parts: the fault diagnosis system of rotating parts and the fault diagnosis system of NC system.The fault diagnosis system of rotating parts in machining center is based on vibration signal processing, and the fault features are extracted to achieve the goal of fault diagnosis.First, the fault vibration signal is processed.Time domain analysis mainly includes statistical characteristic parameter analysis and correlation function analysis.The frequency domain analysis includes amplitude spectrum analysis, power spectrum analysis, cepstrum analysis and detailed spectrum analysis.In addition, wavelet analysis method is introduced to process the vibration signal of machining center to extract the fault features for user fault diagnosis. The diagnosis system is designed by using MATLAB software.The accuracy of the finite element model is verified by the modal test of the machining center turntable.The results of correlation analysis between the natural frequency calculation and the test value of the turntable can be used for the fatigue analysis of the finite element model, and the life of the turntable designed can reach the expected design value.The fault diagnosis system of NC system in machining center is to diagnose the alarm provided by NC system according to the fault case base.The establishment of the fault case database needs three aspects: user machine tool self-defined fault information, Siemens 840D fault alarm manual, fault status of machining center, fault cause, harm degree and so on.After the fault of machining center is sorted out, the man-machine interaction interface is designed with programming software and the function of fault classification and statistics is added, which has some reference value for fault prevention decision.
【学位授予单位】：昆明理工大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG659

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