圆盘式刀库状态监控系统研制

发布时间：2018-06-25 07:17

本文选题：圆盘式刀库 + 故障分析　；参考：《吉林大学》2015年硕士论文

【摘要】：生产制造业的大力发展促使了国家经济的不断进步，随之也拉动了数控机床的需求和销量，使得其作用日益凸显，应用领域也越来越广泛。近年来，国家对数控装备的投入逐渐增大，我国数控机床的发展也取得了明显进步，逐步向多功能、高精度、高效率的方向发展。然而，国产数控机床同国外同类产品相比，仍存在不小差距，尤其是在高端数控机床领域，机床的先进功能和性能指标不能维持，可靠性水平偏低，严重影响了国产数控机床的声誉和市场占有率。功能部件的可靠性对数控机床整机的可靠性有重要影响，如数控车床的转塔刀架、加工中心的刀库及机械手等是国产数控机床可靠性的薄弱环节，成为影响整机可靠性水平的关键部件。通过搭建数控机床关键功能部件可靠性试验系统，对机床的关键功能部件进行长期的实验室可靠性台架试验，暴露和激发其潜在的故障和薄弱环节，提出有效的改进建议和措施并实施，对促进机床功能部件乃至机床整机可靠性水平的提升具有重要的意义。本文以国产加工中心某YP系列圆盘式刀库为研究对象，结合实验室现有圆盘式刀库可靠性试验系统，，完成了刀库可靠性试验过程状态监控系统的研制与开发，该系统不仅有利于提高刀库可靠性试验系统的自动化能力和自我保护能力，也为后续进行刀库运行过程的故障预警和故障诊断奠定了基础。论文首先对圆盘式刀库的具体结构和功能进行了研究分析，并结合长期的现场跟踪试验数据，深入剖析了圆盘式刀库常见故障类别以及故障发生的原因。在刀库故障原因分析的基础上，论文研究了圆盘式刀库状态监控系统的功能需求与设计思路。根据刀库结构特点和监控信号的不同，确定了监控方案，研制了圆盘式刀库状态监控硬件系统。论文基于可视化编程语言Visual Basic6.0和Access数据库开发了圆盘式刀库状态监控系统软件。该软件面向对象设计、具有较好的人机交互性，主要包括用户信息管理、试验信息管理、状态信号监控等模块。用户信息管理的设计，实现了多用户需求，保证了系统操作的规范化和安全性。试验信息管理的设计为用户了解、查询和更新整个系统的配置信息以及刀库的故障状态等信息提供了便捷的通道。作为系统的核心部分，状态信号监控模块的设计充分利用了传感器技术和计算机技术的特点，实现了对刀库电流、温度、振动信号的实时高速采集和存储；并结合数字信号滤波技术和时域分析技术，实现了对采集信号的波形输出预处理和特征量提取等功能。此外，通过上位机VB编程和下位机PLC设计实现了对刀库掉刀状态信号的实时监控程序开发，并对换刀过程中发生的掉刀故障现象进行报警。整个软件系统设计中进行了Access数据库的开发，保证了系统数据信息的完整性与访问便捷性。通过大量的综合试验分析可知，圆盘式刀库状态监控系统能够实现对刀库可靠性试验系统信息的操作与管理以及状态信号监控等功能，达到了设计目的，对提高圆盘式刀库的可靠性具有重要的应用价值。
[Abstract]:The development of the production and manufacturing industry has promoted the continuous progress of the national economy, which has also led to the demand and sales of CNC machine tools, which makes its role increasingly prominent, and the application field is becoming more and more extensive. In recent years, the investment of the national CNC equipment has been gradually increased, and the development of CNC machine beds has also made obvious progress and gradually to multifunction, However, the domestic CNC machine tools still have no small gap compared with the similar products abroad. Especially in the field of high-end CNC machine tools, the advanced functions and performance indexes of the machine tools can not be maintained and the level of reliability is low, which seriously affects the reputation and market share of the domestic CNC machine tools. The dependability has an important influence on the reliability of the CNC machine tool, such as the turret tool frame of the CNC lathe, the tool library and the manipulator of the machining center, which are the weak links of the reliability of the CNC machine tools made in China, and become the key components that affect the reliability level of the whole machine.
By setting up the reliability test system of key functional components of CNC machine tools, a long-term laboratory reliability bench test is carried out on the key functional parts of the machine tool, and the potential faults and weak links are exposed and stimulated, and the effective improvement suggestions and measures are put forward to promote the reliability level of the machine bed functional components and the machine tools. In this paper, the development and development of the state monitoring system for the reliability test process of the tool storehouse are completed with a YP series disc tool library of a domestic manufacturing center as the research object and the existing disk type tool library reliability test system in the laboratory. The system is not only beneficial to improve the automation of the tool library reliability test system. Ability and self protection ability also lay a foundation for subsequent fault prediction and fault diagnosis in the operation of tool magazine.
In this paper, the specific structure and function of the disc knife library are studied and analyzed, and the common fault categories and the causes of the failure are analyzed in depth with the long-term field tracking test data.
On the basis of the analysis of the cause of the fault of the knife base, the paper studies the function requirement and design idea of the state monitoring system of the disc knife library. According to the structure characteristics of the knife base and the difference of the monitoring signal, the monitoring scheme is determined, and the hardware system of the state monitoring and control of the disc type knife library is developed.
Based on the visual programming language Visual Basic6.0 and Access database, the paper developed a disc tool database state monitoring system software. The software is designed with a good human-computer interaction, including user information management, test information management, state signal monitoring and so on. The design of user information management has realized multi users. The design of test information management provides a convenient channel for users to understand, query and update the configuration information of the whole system and the failure state of the tool library. As the core part of the system, the design of the state signal monitoring module makes full use of the sensor technology and calculation. The characteristics of the machine technology realize the real-time high-speed acquisition and storage of the current, temperature and vibration signals of the knife library, and combine the digital signal filtering and the time domain analysis technology to realize the function of the waveform output preprocessing and the feature extraction of the acquisition signal. In addition, the tool library is dropped by the VB programming of the upper computer and the PLC design of the lower computer. The real-time monitoring program of the knife state signal is developed, and the phenomenon of the failure of the cutter in the process of changing the knife is alarm. The development of the Access database is carried out in the whole software system design, which ensures the integrity of the system data information and the convenience of the access.
Through a large number of comprehensive test analysis, it can be seen that the disc type tool bank state monitoring system can realize the operation and management of the information of the tool library reliability test system and the state signal monitoring and so on. It has achieved the design goal and has important value for improving the reliability of the disc knife library.
【学位授予单位】：吉林大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG659

【参考文献】