Research And Application Of Workshop Tool Abnormality Monitoring Network System Based On EtherCAT

Tool abnormality monitoring is an important technology in high-volume CNC workshops.Researching tool abnormality monitoring technology can not only improve the quality and precision of machining,but also improve the service life of the tool,reduce the failure rate of the machine tool and the rejection rate of product,and thus improve the economic benefits.In this paper,the four kinds of tool abnormal states(tool missing,tool wear,tool breakage,tool overload)that may occur during the machining process are studied in the NC workshop tool abnormality monitoring,and a unified database is constructed to realize simultaneous monitoring of multiple machine tools.The specific work is as follows:Aiming at the process characteristics of large-scale CNC production and the defects of tool change method,the mechanism of tool abnormality is analyzed in detail,the influence of process parameters on cutting force and the tool abnormality monitoring method based on spindle current are studied.And the extraction of the eigenvalues of the tool anomalies is realized,and the smoothing parameter selection scheme is determined.Aiming at the solution requirements of the tool abnormality monitoring system,the real-time data transmission and control method of tool abnormality monitoring based on IO module,EtherCAT,TCP/IP,Oracle Database and other technologies was studied,and the machine-based PMC and machining were proposed.Machine control strategy for NC programs.The characteristics of the state signal of the machine tool are analyzed.The process identification and the signal interception method based on the machine state and the splicing method of the processing segment feature value are studied.The tool abnormality identification model is constructed.The performance and reliability of the hardware system based on Beckhoff are analyzed,and the hardware construction of the shop tool abnormality monitoring system based on Beckhoff is realized.The software framework of the monitoring system is designed,and three software modules such as data acquisition,signal analysis and processing module,human-computer interaction and database module are developed.The data interaction between each module is analyzed,and the implementation strategy is proposed.Based on the statistical analysis of long-term tool monitoring data,tool life management is realized.Finally,a complete CNC shop processing anomaly monitoring system was completed.The application verification of the CSR high-speed rail frame processing production line was carried out.The monitoring functions of four tool anomalies were verified,and the influence of actual site conditions on tool abnormality monitoring was studied.Finally,based on Oracle Database and TPC/IP technology,the tool abnormality monitoring visual display of the entire frame processing production line is realized.