CN1015093B - Method and apparatus for monitoring and controlling acoustic emission cutter - Google Patents
Method and apparatus for monitoring and controlling acoustic emission cutterInfo
- Publication number
- CN1015093B CN1015093B CN 89108832 CN89108832A CN1015093B CN 1015093 B CN1015093 B CN 1015093B CN 89108832 CN89108832 CN 89108832 CN 89108832 A CN89108832 A CN 89108832A CN 1015093 B CN1015093 B CN 1015093B
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- CN
- China
- Prior art keywords
- signal
- envelope signal
- peak
- peak value
- acoustic emission
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- Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)
- Measurement Of Mechanical Vibrations Or Ultrasonic Waves (AREA)
Abstract
一种声发射刀具综合监视方法，其特征是用声发射信号的振铃记数，一次包络信号幅值的均值，一次包络信号的峰值，一次包络信号的微分峰峰值，二次包络信号的峰值，一次包络信号峰值记数，二次包络信号波延续时间等七个特征参数作为判断刀具工况的指标，按此法制成的声发射刀具综合监视仪其漏报率及误报率低，抗现场机、电、声、磁等瞬态干扰能力强，并可用于多种机床、多工种，能自动适应多刀具，多工种阀值设定及增益调整。
A comprehensive monitoring method for acoustic emission cutting tools, which is characterized in that the ringing count of the acoustic emission signal, the mean value of the amplitude of the primary envelope signal, the peak value of the primary envelope signal, the differential peak-to-peak value of the primary envelope signal, and the secondary envelope signal Seven characteristic parameters, such as the peak value of the envelope signal, the peak count of the primary envelope signal, and the duration of the secondary envelope signal wave, are used as indicators for judging the working conditions of the cutting tool. The false alarm rate and The false alarm rate is low, and the ability to resist transient interference such as on-site machine, electricity, sound, and magnetism is strong, and it can be used for various machine tools and types of work, and can automatically adapt to multi-tool, multi-type threshold setting and gain adjustment.
Description
The present invention relates to the real time monitoring method and apparatus of working angles tool failure, wearing and tearing and other operating mode.
The present invention is that Chinese patent application number is the continuation application of 89100419.X.
The LINE REAL TIME MONITORING of working angles cutter is modern manufacturing system and heavy-duty machinery manufacturing and large-scale valuable workpiece cutting apparatus and workpiece safety, improve plant factor and product quality, reduce labor intensity, reduce cost and rejection rate, reduce material consumption, realize one of gordian technique of unmanned full-automatic processing.
The main technical requirements of Tool in Cutting process operating mode real-time monitoring system and device has: 1. with enough operating accuracies (fail to report with rate of false alarm all should＜5～10%) realize damaged, inordinate wear (or wearing and tearing) and other cutter operating mode function for monitoring; 2. operate as normal under numerical control workshop and common machine job shop condition stably has that strong anti-scene is mechanical, electrical, magnetic, the capable and experienced anti-ability of acoustic jamming, particularly transient state; 3. fast, real-time to transient state cutter operating mode such as damaged response speed; 4. have excellent application performance energy-adaptation type and work post many, debug simple and reliablely, do not influence selecting for use of normal machining condition (comprising cutting data, cooling-lubricant condition etc.), use good in economic efficiency, and installation cost moderate (≤1/10 equipment price).But at recent two decades, no matter be directly or indirect method also the system of neither one widespread use have above-mentioned repertoire requirement.Based on optical image, contact is difficult to practicability with the surveillance of radiation technique, and power or current identification sensitivity are low; Cutting force or moment method are hampered by determining of recognition threshold; Though vibration and acoustic-emission have application prospect, but still difficulty satisfies above-mentioned requirements fully.Chinese invention patent, application number 86104652 utilize that the fuzzy Judgment question blank is finished multi-path, the research and development of the micro computer real-time identifying system technical unit device of the AE signal that obtains at many levels, have reached higher operating accuracy.This patent is by the AE sensor, amplify and the acoustic emission waveform treating apparatus of frequency-selecting detection the AE signal, interface circuit and microcomputer and display that cutter is judged unusually formed.Its principle of work is for obtaining the AE signal of working angles AE sound source with the AE sensor, behind amplification and frequency-selective filtering, carry out the acoustic emission waveform conversion process, obtain fast detection, slow detection, low-frequency pulse and the multi-path of high-frequency impulse, multi-level integrated information, compare based on the fuzzy Judgment model by microcomputer again according to these information, these information are discerned, to determine the unusual service condition of cutter.But by flexible manufacturing cell (FMC), flexible manufacturing system (FMS) and the practicability cutter supervision technical requirement of computer integrated manufacturing system (CIM) to automatic processing machine tool, this application still has following weak point: (1) operating accuracy is high not enough, promptly to improve the warning success ratio, reduce rate of false alarm; (2) alarm time is also longer; (3) anti-transient state strong jamming ability is relatively poor; (4) mainly be applicable to single operation operating condition monitoring.
The object of the present invention is to provide a kind of being suitable for, cutting-tool by sound emission integrated supervision method cutter operating mode real time monitoring, that response speed is fast, operating accuracy is high, anti-glitch ability is strong and use the monitoring arrangement of this method in the automated machine tool continuous working of multicutter conversion to multiple operation (kind).
Technical solution of the present invention provides a kind of tool failure of using, acoustic emission signal during wearing and tearing monitors the method for cutter operating mode, its particular content is by sound wave emissions, the sensing of acoustic signals, amplify, frequency-selecting, filtering, the step that acoustic emission signal forms integrated information and microcomputer utilizes integrated information to carry out the unusual judgement of cutter is formed, and it is characterized in that integrated information is by acoustic emission signal " ring numeration ", " average of first enveloped signal amplitude ", " peak value of first enveloped signal ", " the differential peak-to-peak value of first enveloped signal ", " peak value of twice-enveloping signal ", " numeration of first enveloped signal peak ", " twice-enveloping signal wave perdurability " formed.
Cutting-tool by sound emission integrated supervision device of the present invention is detected by acoustic emission signal and gives processing unit, comprising calibrate AE sensor, prime amplifier, Hi-pass filter, main amplifier, bandpass filter, signal and general purpose microprocessor interface unit, microprocessor, display, crosslinked transmission is formed with warning output unit and anti-jamming power-supply, it is characterized in that input comprises in the processing unit that ring forms circuit with giving, envelope forms circuit, programmable amplifier, twice-enveloping forms circuit, the programmable threshold comparer, differential signal forms circuit to be formed, and this microprocessor is to " ring numeration ", " average of first enveloped signal amplitude ", " peak value of first enveloped signal ", " the differential peak-to-peak value of first enveloped signal ", " twice-enveloping signal peak ", " numeration of first enveloped signal peak ", " the ripple perdurability of twice-enveloping signal " carries out the microcomputer of intelligent identification.
The factor that produces acoustic emission signal in the Tool in Cutting process is a lot, and its signal has various features again, all independent a kind of sound emission signal characteristics are difficult to as the operating mode of concluding cutter, must be to the various features of AE signal analysis-by-synthesis in addition, the working condition that could reflect cutter preferably reduces the rate of failing to report rate of false alarm.The feature of AE signal has following several:
1. ring numeration: the number that promptly surpasses preset threshold value AE signal in the unit interval.The waveform of AE signal is seen accompanying drawing 1a.This signal through amplification, filtering, prune that it is lower than the signal of threshold level value, pass through again after the shaping the ringdown oscillogram, as Fig. 1 b.
2. first enveloped signal: be that the AE signal is carried out envelope detection gained signal.As Fig. 1 c.
3. the average of first enveloped signal amplitude: be in the unit interval, the average of first enveloped signal amplitude.
4. the peak value of first enveloped signal: as the Ap among Fig. 1 c
1, Ap
2
5. the differential peak-to-peak value of first enveloped signal: be about to the first enveloped signal and carry out differential, promptly get the Ad among Fig. 1 g with differentiating circuit
1, Ad
2, Ad
3, Ad
4
6. twice-enveloping signal: be about to the first enveloped signal and form, as Fig. 1 d through low-pass filtering.
7. the peak value of twice-enveloping signal: promptly as the SA among Fig. 1 d
1, SA
2
8. first enveloped peak value numeration: Fig. 1 f is first enveloped peak value numeration signal, when its production process is compared the amplitude of (as Fig. 1 e) twice-enveloping signal after the peak value of first enveloped signal surpasses the constant k value that superposeed for the twice-enveloping signal value of Fig. 1 d being added after the constant k value with the first enveloped signal among Fig. 1 c, promptly get a first enveloped peak value numeration, the k value is for cutting the fixed values of operating modes by difference.
9. twice-enveloping signal wave perdurability: by the time span of the twice-enveloping signal wave that preset threshold value intercepted, as the t of Fig. 1 d
A2, determine the threshold value that presets by operating mode.
The feature of above-mentioned several AE signals is the working condition in reflection Tool in Cutting process aspect certain all, when several characteristic parameters comprehensively reach a certain value the time, promptly show the breakage or the work condition abnormality of cutter.
Illustrate that accompanying drawing is as follows:
Fig. 1 is an oscillogram.
A is that acoustic emission (AE) oscillogram b is a ring numeration oscillogram
C is that first enveloped oscillogram d is the twice-enveloping oscillogram
E is first enveloped peak value numeration oscillogram for first enveloped peak value numeration formation figure f
G is a first enveloped differential peak-to-peak value oscillogram
Fig. 2 is characteristic plane figure.
Fig. 3 is a cutting-tool by sound emission integrated supervision instrument fundamental diagram.
Fig. 4 is a cutting-tool by sound emission integrated supervision instrument software block diagram.
Fig. 5 is a cutting-tool by sound emission integrated supervision instrument system block diagram.
Fig. 6 is the preamplifier circuit schematic diagram.
Fig. 7 is the main amplifier circuit schematic diagram.
Fig. 8 is the bandwidth-limited circuit schematic diagram.
Fig. 9 forms circuit theory diagrams for ring.
Figure 10 forms circuit theory diagrams for first enveloped.
Figure 11 is the signal processing circuit unit schematic diagram.Wherein
I-be the programmable amplifier circuit theory diagrams.
II-be that twice-enveloping forms circuit theory diagrams.
III-be the differentiating circuit schematic diagram.
IV-be first enveloped peak value numeration circuit theory diagrams.
Accompanying drawings principle of work of the present invention is as follows:
Y=a
1l
1+ a
2l
2+ a
3(regional I)
Y=b
1l
1+ b
2l
2+ b
3(regional II) represents (Fig. 2).
To different L
1, L
2Can on characteristic plane, form different Y values.In order to represent that the cutter operating mode is normal and unusual, the Y value should be divided into two classes.By a large amount of cutting experiment statisticss, can obtain a Y-Y broken line as the identification separatrix, the Y-Y broken line with the right side be exceptions area, on the Y-Y broken line left side be normally to distinguish.Therefore to a certain specific L
1, L
2Value can calculate its Y value, checks that then its Y value is the right side or the left side at the Y-Y broken line, and is as then represent unusual (being tool failure) on the right side, normal as then representing on the left side.The Y-Y broken line is called the decision-making line.
If three characteristic signal L are arranged
1, L
2, L
3(three-dimensional) characteristic plane when then being equivalent to two dimension is feature space.And also can calculate Different L by linear equation
1, L
2, L
3The time the Y value.Equally also can be divided into different Y values two classes (normal and unusual), and can divide by a folding plane (folding face).On the plane on one side be normally to distinguish, another side be exceptions area, this plane promptly is called decision surface (the decision-making line when being equivalent to two dimension).
Further characteristic signal is expanded to seven (L
1, L
2... L
7) then these seven eigenwerts also can be by linear equation Y=f(
) calculate the Y value, and be distributed in the space of a broad sense (septuple space).And also can be divided into two groups (normally district and exceptions area) by a decision surface (folding face) the Y value that each is different.
The linear equation Y=f(that adopts among the present invention
) be specially:
Wherein: a
1A
8, b
1B
8Coefficient is by different operating mode decisions.
For example: when monitoring for the tapping of n=255rpm machine, L
1Be ring numeration, L
2Be the average of first enveloped signal amplitude, L
3Be the peak value of first enveloped signal, L
4Be the differential peak-to-peak value of first enveloped signal, L
5Be twice-enveloping signal peak, L
6Be the numeration of first enveloped peak value, L
7Be twice-enveloping signal wave perdurability, the coefficient of equation Y is respectively:
a
1＝b
1＝1 a
2＝b
2＝-5 a
3＝b
3＝1
a
4＝b
4＝0.8 a
5＝b
5＝4 a
6＝b
6＝64
a
7＝b
7＝0.5 a
8＝b
8＝-213
Table is measured value on the XH754 machining center
The operating mode nominal situation is unusual
L 0 39
L 7 7
L 8 60
L 4 82
L 8 13
L 0 1
L 0 15
Y -205.2 +39.7
Recognition result is normally unusual
Characteristic signal (L
1L
7) i.e. " ring numeration ", " average of first enveloped signal amplitude ", " peak value of first enveloped signal ", " the differential peak-to-peak value of first enveloped signal ", " twice-enveloping signal peak ", " numeration of first enveloped signal peak ", " the ripple perdurability of twice-enveloping signal ".
Fundamental diagram such as Fig. 3 of the cutting-tool by sound emission integrated supervision instrument of making by above-mentioned principle of the present invention.
This instrument is finished every processing by hardware, software.
Receive the AE signal through amplifying by sensor, bandpass filtering carries out pre-service by hardware, obtains the ring numeration, first enveloped signal, twice-enveloping signal, the differential of first enveloped signal.Carry out feature extraction then,, obtain the ring counter value, first enveloped signal, twice-enveloping signal, the differential of first enveloped signal by software sampling.Carry out feature extraction then,, obtain the ring counter value, first enveloped differential peak-to-peak value, first enveloped peak value counter value (i.e. seven eigenwerts) by software sampling.Parameter estimation part promptly from process information obtain job operation information (be car, mill, the code of brill etc.) from feature extraction partly obtain first enveloped amplitude average with determine machining status information K(at a high speed or low speed), thereby estimate a
1, a
2, a
3A
8, b
1, b
2B
8And the isoparametric numerical value of K value (by learning in the expert knowledge library priori), determine used Y=f(in conjunction with priori then
) equation.In sorter, use by the determined Y=f(of priori by the characteristic ginseng value that is extracted
) equation carries out computing and draw the Y value, compare, item be normal as Y＜0, Y 〉=0 item be unusual, as for unusually then starting alarm equipment alarm, as monitoring for normally then repeating.
Finish the software block diagram of above-mentioned functions and see Fig. 4.
Open interruption 1 time-delay after the master routine initialization and prepare to accept interruption, then interrupt 1 and promptly do data sampling, take the ring numeration, first enveloped, twice-enveloping, first enveloped differential, five parameters such as first enveloped peak value numeration, and restart thief hatch are constantly sampled making it.Time-delay finishes the back and carry out parameter estimation in master routine, to determine b
1, b
2B
8, a
1, a
2B
8With the parameter of K value etc. and determine Y=f(
) form, opens interrupters 1 and waiting for then, five parameters of interrupting 2 pairs of sampling gained are carried out the parameter attribute extraction and are obtained seven above-mentioned characteristic parameters.Press Y=f(
) concrete equation calculate carry out Y＜0 or Y 〉=0 then comparison to make the judgement of whether reporting to the police, as for unusually then starting alarm equipment alarm, as for checking then normally whether cutting state changes (be whether cutting speed changes, whether job operation changes).Cutting state change sign is then put in change as cutting state.Return master routine then, master routine is checked the cutting state sign, as indicates constant interruption next time of then waiting for, changes as sign, then will reappraise parameter, Y=f(
) equation, return the repetition monitoring facilities then.
For finishing above-mentioned functions, system chart such as Fig. 5 of the comprehensive cutter monitor of this acoustic emission.
This instrument is divided into five major parts: (I) input and pretreatment unit (1～11); (II) signal and mini-computer interface unit (12); (III) universal miniature computing system (13); (IV) crosslinked transmission I/O and warning output unit (14,15); (V) anti-interference power supply system (16,17).
[1] for broadband piezoelectric crystal AE sensor frequency band be 100KHZ～1MHZ(≤± 10dB)
[2] [3] are prime amplifier, and [2] are amplifier, gain to be 20dB or 40dB, and [3] are 100KHZ for its cutoff frequency of Hi-pass filter, and the decay gradient is 10dB/ocT.[2] the prime amplifier input conversion noise of [3] composition is less than 4.5 μ V(RMS), its circuit theory diagrams are Fig. 6.
[4] main amplifier, gain are 10～40dB.(Fig. 7)
[5] be bandpass filtering cutoff frequency high pass 300KHZ, low pass 1MHZ, attenuation slope 24dB/ocT(Fig. 8).
[6] ring forms circuit (Fig. 9).
[7] envelope forms circuit (Figure 10).
Form signal pre-processing circuit such as Figure 11 by [4] [5] [6] [7].
[8] programmable amplifier (I among Figure 11), purpose are to guarantee that signal is among the suitable range of A/D.
[9] twice-enveloping forms circuit (II among Figure 11).
[10] differential signal forms circuit (III among Figure 11).
[11] programmable threshold comparer forms envelope counting (IV among Figure 11).
[12] contain signal and microcomputer interfaces such as A/D, D/A, CTC.
[13] microsystem.
[14] crosslinked mouthful with the lathe exchange message, optional RS232 or relay.
[15] warning is exported, and alerting signal is delivered to the alarm lamp and the buzzer of instrument panel.
[8]～[15] microcomputer of Zu Chenging is the feature selecting and the signal processing circuit unit on basis, circuit diagram such as Fig. 6.
[16] exchange anti-jamming power-supply (commercially available)
[17] D.C. regulated power supply (commercially available)
By the present invention to the various features of AE signal in addition the method for analysis-by-synthesis judge that the cutting-tool by sound emission monitoring instrument that the method for cutter operating mode is made can reduce rate of failing to report and rate of false alarm.Cutting-tool by sound emission integrated supervision instrument rate of failing to report of the present invention, rate of false alarm are low, and glitch abilities such as anti-on-the-spot mechanical, electrical, magnetic, sound are strong, and can be used for multiple lathe and multiplex's kind, can adapt to the multicutter multiplex (MUX) automatically and plant threshold setting and gain adjustment.
Claims (2)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 89108832 CN1015093B (en) | 1989-11-30 | 1989-11-30 | Method and apparatus for monitoring and controlling acoustic emission cutter |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 89108832 CN1015093B (en) | 1989-11-30 | 1989-11-30 | Method and apparatus for monitoring and controlling acoustic emission cutter |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1041721A CN1041721A (en) | 1990-05-02 |
| CN1015093B true CN1015093B (en) | 1991-12-18 |
Family
ID=4857755
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN 89108832 Expired CN1015093B (en) | 1989-11-30 | 1989-11-30 | Method and apparatus for monitoring and controlling acoustic emission cutter |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN1015093B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1045738C (en) * | 1992-09-29 | 1999-10-20 | 清华大学 | Cutter failure comprehensive monitoring and controlling method and device |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102008045470A1 (en) | 2008-09-03 | 2010-03-04 | Wirtgen Gmbh | Method for determining the state of wear |
| CN102001023B (en) * | 2010-12-24 | 2013-10-16 | 沈阳飞机工业（集团）有限公司 | Tool wear detector |
| CN105021706B (en) * | 2015-07-16 | 2018-11-27 | 郑州磨料磨具磨削研究所有限公司 | A kind of grinding wheel broken state early warning identification device and method |
-
1989
- 1989-11-30 CN CN 89108832 patent/CN1015093B/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1045738C (en) * | 1992-09-29 | 1999-10-20 | 清华大学 | Cutter failure comprehensive monitoring and controlling method and device |
Also Published As
| Publication number | Publication date |
|---|---|
| CN1041721A (en) | 1990-05-02 |
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