CN108490876B - Method for improving synchronization accuracy of numerical control machining monitoring threshold and signal - Google Patents
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Abstract
Translated fromChinese
Description
Translated fromChinese技术领域technical field
本发明涉及数控加工过程监控技术领域，具体涉及一种提高加工实时监控过程中阈值与信号同步精确性的方法。The invention relates to the technical field of numerical control machining process monitoring, in particular to a method for improving the synchronization accuracy of thresholds and signals in the process of real-time machining monitoring.
背景技术Background technique
数控加工监控过程中，为了实现对信号的监控，需要对实时采集的信号设置正常的阈值区间，之后依次读取和对比阈值和信号，判断加工状态。目前针对数控加工监控的研究绝大多数都是针对信号处理的方向进行，根据之前进行的研究表明，在信号的采集过程中，采集的频率会出现波动，会对监控阈值与信号的同步准确性产生影响。In the process of CNC machining monitoring, in order to monitor the signal, it is necessary to set a normal threshold interval for the signal collected in real time, and then read and compare the threshold and signal in turn to judge the processing status. At present, most of the research on CNC machining monitoring is carried out in the direction of signal processing. According to the previous research, in the process of signal acquisition, the frequency of acquisition will fluctuate, which will affect the synchronization accuracy of the monitoring threshold and the signal. make an impact.
阈值与信号的同步是指对信号进行监控时，将当前加工状态采集的信号与对应状态下的阈值进行比较。对于阈值与信号的同步，主要存在两种方法：一种是基于坐标，即在NC (Numerical Control，数字控制)加工监控过程中，使用具有机床坐标信息的监控阈值，并同时采集机床的实时坐标与监控信号，通过对比阈值和信号的坐标实现阈值和信号的对应[1][2]。这种方式往往由于监控阈值与实时信号的坐标精度不足，而导致监控精度不高甚至失效。另一种是基于绝对时间，使用具有机床加工时间信息的监控阈值，并与实时信号以零件某加工过程的启动时间为基准进行同步，如德国ARTIS监控系统中的标准监控模式[3]-[6]。但是在这种同步方法中信号采集频率容易出现波动，导致长时间监控后产生误差累积，无法实现信号与监控阈值的准确同步。The synchronization of the threshold value and the signal refers to comparing the signal collected in the current processing state with the threshold value in the corresponding state when monitoring the signal. For the synchronization of threshold and signal, there are two main methods: one is based on coordinates, that is, in the process of NC (Numerical Control, digital control) machining monitoring, the monitoring threshold with machine tool coordinate information is used, and the real-time coordinates of the machine tool are collected at the same time. With the monitoring signal, the correspondence between the threshold and the signal is achieved by comparing the coordinates of the threshold and the signal[1][2] . This method often leads to low monitoring accuracy or even failure due to insufficient monitoring threshold and coordinate accuracy of real-time signals. The other is based on absolute time, using monitoring thresholds with machine tool processing time information, and synchronizing with real-time signals based on the start time of a part processing process, such as the standard monitoring mode in the German ARTIS monitoring system[3]-[ 6] . However, in this synchronization method, the signal acquisition frequency is prone to fluctuations, which leads to the accumulation of errors after long-term monitoring, and the accurate synchronization of the signal and the monitoring threshold cannot be achieved.
[1]Tong L,Yan P,Liu F.Monitoring Computer Numerical Control MachiningProgress Based on Information Fusion[J].Chinese Journal of MechanicalEngineering,2011,24(6):1074-1081.[1]Tong L,Yan P,Liu F.Monitoring Computer Numerical Control MachiningProgress Based on Information Fusion[J].Chinese Journal of Mechanical Engineering,2011,24(6):1074-1081.
[2]Kim D H,Song J Y.Ubiquitous-based mobile control and monitoring ofCNC machines for development of u-machine[J].Journal of Mechanical Scienceand Technology, 2006,20(4):455-466.[2] Kim D H, Song J Y.Ubiquitous-based mobile control and monitoring of CNC machines for development of u-machine[J].Journal of Mechanical Science and Technology, 2006,20(4):455-466.
[3]朱绍维,牟文平,汤立民,杜丽.融合工艺信息的复杂零件加工状态识别方法[J].中国机械工程,2016,27(11):1479-1483.[3] Zhu Shaowei, Mu Wenping, Tang Limin, Du Li. Recognition method of processing state of complex parts with process information [J]. China Mechanical Engineering, 2016, 27(11): 1479-1483.
[4]吴明杰,唐恒.浅谈ARTIS刀具监控系统在实际生产中的应用[J].装备制造技术,2017(4):106-108.[4] Wu Mingjie, Tang Heng. Talking about the application of ARTIS tool monitoring system in actual production [J]. Equipment Manufacturing Technology, 2017(4):106-108.
[5]朱绍维,李卫东,汤立民,杜丽.ARTIS刀具监控系统在航空结构件铣削加工中的应用[I].中国机械工程,2016,27(15):2040-2043.[5] Zhu Shaowei, Li Weidong, Tang Limin, Du Li. Application of ARTIS tool monitoring system in milling of aerospace structural parts [I]. China Mechanical Engineering, 2016, 27(15): 2040-2043.
[6]邓凌,许翠芳,乔永忠.ARTIS刀具监控系统在数控机床上的开发应用[J].制造技术与机床,2013(2):121-124.[6] Deng Ling, Xu Cuifang, Qiao Yongzhong. Development and application of ARTIS tool monitoring system on CNC machine tools [J]. Manufacturing Technology and Machine Tools, 2013(2):121-124.
发明内容SUMMARY OF THE INVENTION
针对上述问题，本发明的目的在于提供一种能够对出现频率波动的信号采集过程进行处理，不影响后续监控的提高加工实时监控过程中阈值与信号同步精确性的方法。技术方案如下：In view of the above problems, the purpose of the present invention is to provide a method for improving the synchronization accuracy of the threshold value and the signal in the real-time monitoring process of processing, which can process the signal acquisition process with frequency fluctuation without affecting the subsequent monitoring. The technical solution is as follows:
一种提高数控加工监控阈值与信号同步精确性的方法，包括以下步骤：A method for improving the synchronization accuracy of a numerical control machining monitoring threshold and a signal, comprising the following steps:
步骤1：机床示教加工时，通过实时采集的信息计算每个NC程序段采集数据个数及阈值个数；Step 1: During the teaching and processing of the machine tool, the number of data collected and the number of thresholds for each NC block are calculated through the information collected in real time;
步骤2：当机床处在监控模式时，在NC程序每一段完成后，实时计算同步误差；Step 2: When the machine tool is in the monitoring mode, after each segment of the NC program is completed, the synchronization error is calculated in real time;
步骤3：对同步误差计算结果进行分析，判定监控阈值的超前、滞后及正常状态；Step 3: Analyze the synchronization error calculation result to determine the leading, lagging and normal state of the monitoring threshold;
步骤4：如果出现监控阈值的超前及滞后，通过误差消除方法对同步误差进行消除。Step 4: If there is a lead and a lag of the monitoring threshold, the synchronization error is eliminated by an error elimination method.
进一步的，所述计算每个NC程序段采集数据个数及阈值个数的方法为：Further, the method for calculating the number of data collected by each NC program segment and the number of thresholds is:
加工某NC程序段的加工时间Tc为：The machining time Tc for machining a NC block is:
式中：xm、ym、zm为当前NC程序段结束时的工件坐标；xm-1、ym-1、zm-1为上一NC程序段结束时的工件坐标；F为当前NC程序段的进给速度；Where: xm , ym , zm are the workpiece coordinates at the end of the current NC block; xm-1 , ym-1 , zm-1 are the workpiece coordinates at the end of the previous NC block; F is the The feedrate of the current NC block;
则在每段NC程序段加工过程中采集数据的个数m为：Then the number m of data collected during the processing of each NC block is:
式中：f为数据采集频率；Where: f is the data collection frequency;
在每段NC程序段加工过程中阈值个数a为：The threshold number a in the machining process of each NC block is:
式中：n为计算单个阈值需要的数据个数。In the formula: n is the number of data required to calculate a single threshold.
更进一步的，所述同步误差即数据采集的信号与阈值之间的时间误差Δt：Further, the synchronization error is the time error Δt between the data collected signal and the threshold:
Δt＝t1-t2Δt=t1 −t2
式中：t1为阈值的绝对时间，t2为信号的绝对时间；In the formula: t1 is the absolute time of the threshold, and t2 is the absolute time of the signal;
判断监控阈值状态的方法为：The method for judging the monitoring threshold status is as follows:
●当Δt≤-1/f时，监控阈值超前，该NC程序段对应的信号采样点比对应的监控阈值采样点超前至少一个采样时间间隔，会影响到后续信号的同步；When Δt≤-1/f, the monitoring threshold is ahead, and the signal sampling point corresponding to this NC block is ahead of the corresponding monitoring threshold sampling point by at least one sampling time interval, which will affect the synchronization of subsequent signals;
●当1/f≤Δt时，监控阈值滞后，该NC程序段对应的信号采样点比对应的监控阈值采样点滞后一个采样时间间隔，会影响到后续信号的同步；●When 1/f≤Δt, the monitoring threshold lags, and the signal sampling point corresponding to this NC block lags behind the corresponding monitoring threshold sampling point by a sampling time interval, which will affect the synchronization of subsequent signals;
●当-1/f<Δt<1/f时，信号和对应监控阈值之间有同步误差，但是并未达到一个采样时间间隔，不影响后续信号的同步。●When -1/f<Δt<1/f, there is a synchronization error between the signal and the corresponding monitoring threshold, but it does not reach a sampling time interval, which does not affect the synchronization of subsequent signals.
更进一步的，消除同步误差的方法包括：Further, the method for eliminating synchronization errors includes:
●监控阈值超前时，在采集到下一NC程序段的数据时，将监控阈值和信号各自的NC 程序段段号信息进行对比，直到相同为止，然后继续进行同步；●When the monitoring threshold is ahead, when the data of the next NC block is collected, compare the monitoring threshold and the respective NC block number information of the signal until they are the same, and then continue to synchronize;
●监控阈值滞后时，将本NC程序段的最后一个阈值与信号进行同步，直到下一个NC 程序段；●When monitoring the threshold value lag, synchronize the last threshold value of this NC block with the signal until the next NC block;
对各NC程序段加工结束时的同步误差进行判断，当阈值和信号的个数出现差别时，需要在下一NC程序段重新进行信号与阈值的同步。Judging the synchronization error at the end of each NC block processing, when there is a difference between the threshold value and the number of signals, it is necessary to re-synchronize the signal and the threshold value in the next NC block.
本发明的有益效果是：本发明通过对实时同步误差的计算和判断，采用程序段号对阈值和信号的时间偏差进行校准，减少了监控信号的超前或滞后量；消除同步误差对后续监控的影响，大大提高了监控阈值与信号的时间同步性的有效性，提高了监控准确性。The beneficial effects of the present invention are: by calculating and judging the real-time synchronization error, the present invention uses the program segment number to calibrate the threshold value and the time deviation of the signal, thereby reducing the lead or lag amount of the monitoring signal; It greatly improves the effectiveness of the time synchronization between the monitoring threshold and the signal, and improves the monitoring accuracy.
附图说明Description of drawings
图1是出现Δt≤-1/f情况后的处理方法。Fig. 1 is the processing method after the occurrence of Δt≤-1/f.
图2是出现1/f≤Δt情况后的处理方法。Fig. 2 is the processing method after the situation of 1/f≤Δt occurs.
图3是阈值-时间/阈值-程序段对应的同步误差图。FIG. 3 is a synchronization error diagram corresponding to threshold-time/threshold-segment.
具体实施方式Detailed ways
下面结合附图和具体实施例对本发明做进一步详细说明。本发明方法包括：The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The method of the present invention includes:
步骤1：机床示教加工时，通过实时采集的信息计算每个NC程序段采集数据个数及阈值个数。Step 1: During the teaching and processing of the machine tool, the number of data collected and the number of thresholds in each NC block are calculated through the information collected in real time.
根据采集到的NC程序段始末点的位置坐标计算该段NC的理论加工时间，再根据数据采集频率计算该NC程序段理论采集的数据个数，进而确定该NC程序段需要计算的阈值个数。具体如下：Calculate the theoretical processing time of the NC block according to the collected position coordinates of the start and end points of the NC block, and then calculate the number of theoretically collected data for the NC block according to the data collection frequency, and then determine the number of thresholds that need to be calculated for the NC block. . details as follows:
(1)示教加工时采集数据个数计算过程(1) Calculation process of the number of data collected during teaching and processing
加工某NC程序段的Tc为：The Tc for machining a NC block is:
式中：Tc为某NC程序段的加工时间；xm、ym、zm为当前NC程序段结束的工件坐标；xm-1、 ym-1、zm-1为上一NC程序段结束的工件坐标；F为当前加工段号的进给速度。Where: Tc is the processing time of a certain NC block; xm , ym , zm are the workpiece coordinates at the end of the current NC block; xm-1 , ym-1 , zm-1 are the previous NC The workpiece coordinate at the end of the block; F is the feedrate of the current processing block number.
在每段NC代码加工过程中能采集到数据的个数：The number of data that can be collected during the processing of each NC code:
式中：m为某NC程序段采集数据的个数；f为数据采集频率。In the formula: m is the number of data collected in a NC program segment; f is the data collection frequency.
(2)示教加工时阈值个数计算过程(2) Calculation process of threshold number during teaching processing
由于采集的数据个数不一定能完全被n整除，因此剩下少于n个数据计算出一个阈值。所以计算出阈值个数应向上取整，阈值个数为：Since the number of collected data may not be completely divisible by n, a threshold is calculated with less than n data remaining. Therefore, the number of thresholds calculated should be rounded up, and the number of thresholds is:
式中：a为某NC程序段的阈值个数；n为计算单个阈值需要的数据个数。In the formula: a is the number of thresholds of a certain NC block; n is the number of data required to calculate a single threshold.
步骤2：当机床处在监控模式时，在NC程序每一段完成后，实时计算同步误差。Step 2: When the machine tool is in monitoring mode, the synchronization error is calculated in real time after each segment of the NC program is completed.
通过监控阈值和信号的绝对时间计算二者之间的同步误差Δt计算如下所示。The synchronization error Δt between the monitoring threshold and the absolute time of the signal is calculated as shown below.
Δt＝t1-t2Δt=t1 −t2
式中：t1为阈值的绝对时间；t2为信号的绝对时间；Δt为信号与阈值之间的时间误差。In the formula: t1 is the absolute time of the threshold; t2 is the absolute time of the signal; Δt is the time error between the signal and the threshold.
步骤3：对同步误差计算结果进行分析，判定监控阈值的超前、滞后及正常状态。Step 3: Analyze the calculation result of the synchronization error to determine the lead, lag and normal state of the monitoring threshold.
(1)当Δt≤-1/f(1) When Δt≤-1/f
说明监控阈值超前，该段号对应的信号采样点比对应的监控阈值采样点超前至少一个采样时间间隔，会影响到后续信号的同步。It means that the monitoring threshold is ahead, and the signal sampling point corresponding to this segment number is ahead of the corresponding monitoring threshold sampling point by at least one sampling time interval, which will affect the synchronization of subsequent signals.
(2)当1/f≤Δt(2) When 1/f≤Δt
说明监控阈值滞后，该段号对应的信号采样点比对应的监控阈值采样点滞后一个采样时间间隔，同样会影响到后续信号的同步。Indicates that the monitoring threshold is lagging. The signal sampling point corresponding to this segment number lags behind the corresponding monitoring threshold sampling point by a sampling time interval, which will also affect the synchronization of subsequent signals.
(3)当-1/f<Δt<1/f(3) When -1/f<Δt<1/f
说明信号和对应监控阈值之间有同步误差，但是并未达到一个采样时间间隔，不影响后续信号的同步。It means that there is a synchronization error between the signal and the corresponding monitoring threshold, but it does not reach a sampling time interval, which does not affect the synchronization of subsequent signals.
步骤4：如果出现监控阈值的超前及滞后，通过误差消除方法对同步误差进行消除。Step 4: If there is a lead and a lag of the monitoring threshold, the synchronization error is eliminated by an error elimination method.
如果出现监控阈值的超前及滞后，通过误差消除方法对两种情况下的同步误差分别进行消除，使后续监控过程的同步误差始终在一个合理范围内，提高了监控的准确性。If the monitoring thresholds lead and lag, the synchronization errors in the two cases are eliminated respectively by the error elimination method, so that the synchronization errors in the subsequent monitoring process are always within a reasonable range, and the monitoring accuracy is improved.
(1)监控阈值超前(1) Monitoring threshold ahead
监控阈值超前时，当前加工段号监控阈值采样点比信号采样点的个数多，会把当前段号的阈值对应到下一个段号的信号上。所以在采集到下一NC程序段号的加工数据时，应该将监控阈值和信号的段号信息进行对比，直到相同为止，然后继续进行同步。具体同步方法如图1所示。When the monitoring threshold is ahead, the monitoring threshold sampling points of the current processing segment number are more than the number of signal sampling points, and the threshold value of the current segment number is corresponding to the signal of the next segment number. Therefore, when the processing data of the next NC block number is collected, the monitoring threshold should be compared with the segment number information of the signal until they are the same, and then continue to synchronize. The specific synchronization method is shown in Figure 1.
(2)监控阈值滞后(2) Monitoring Threshold Hysteresis
监控阈值滞后时，如信号在当前NC程序段还能采集到数据，此时可能对应到了下一个 NC程序段的阈值，造成错误。因此将本程序段的最后一个阈值与信号进行同步，直到下一个 NC程序段。具体同步方法如图2所示。When monitoring the threshold value lag, if the signal can still collect data in the current NC block, it may correspond to the threshold value of the next NC block at this time, causing an error. The last threshold value of this block is therefore synchronized with the signal until the next NC block. The specific synchronization method is shown in Figure 2.
在监控时，对各NC程序段加工结束时的同步误差进行判断。当阈值和监控信号的个数出现差别时，需要在下一程序段重新与阈值信号进行同步，以便消除误差。During monitoring, the synchronization error at the end of each NC block processing is judged. When there is a difference between the threshold value and the number of monitoring signals, it is necessary to re-synchronize with the threshold value signal in the next block to eliminate the error.
下面结合具体实例来验证本方法的准确性，采用某刀具磨损监控系统进行数据采集和同步误差计算。监控系统的采集频率为8Hz，即采样周期为1/f＝0.125s。对某零件进行两次重复数控加工，将第一次采集计算的数据作为阈值保存，将第二次采集的数据分别采用绝对时间同步和采用基于NC程序段的相对时间同步方式进行比较，计算两次加工的同步误差。The accuracy of the method is verified by a specific example below, and a tool wear monitoring system is used for data acquisition and synchronization error calculation. The collection frequency of the monitoring system is 8Hz, that is, the sampling period is 1/f=0.125s. Repeat NC machining for a part twice, save the data collected and calculated for the first time as the threshold value, and compare the data collected for the second time using absolute time synchronization and relative time synchronization based on NC blocks respectively, and calculate the two data. Synchronization error of secondary machining.
进行同步误差分析，以信号采样点序号为横坐标、同步误差Δt为纵坐标绘制对比误差图，将加工过程根据程序段号用竖线分为多段，如图3所示。To analyze the synchronization error, draw a comparison error diagram with the signal sampling point serial number as the abscissa and the synchronization error Δt as the ordinate.
通过对比两种同步方式，可以看出在绝对时间同步方法中，由于采样频率的波动导致阈值和信号的同步误差不断累积(最高为1.338s)，导致后期监控失效。而在基于NC程序段相对时间同步方法中，在每个NC程序段结束时计算阈值和信号的同步误差，并对超差程序段进行实时校准，保证下一个程序段开始的同步误差在0.125s以内。By comparing the two synchronization methods, it can be seen that in the absolute time synchronization method, due to the fluctuation of the sampling frequency, the synchronization error of the threshold value and the signal is continuously accumulated (the maximum is 1.338s), which leads to the failure of the later monitoring. In the method based on NC block relative time synchronization, the threshold value and the synchronization error of the signal are calculated at the end of each NC block, and the out-of-tolerance block is calibrated in real time to ensure that the synchronization error at the beginning of the next block is within 0.125s within.
试验中共加工38个程序段，在基于NC程序段的相对时间同步方式中，在NC程序段加工结束时误差超过0.125s而进行误差清除的程序段有6处(竖直虚线处)，有27段整个的加工过程同步误差均少于0.125s，监控过程未失效。相对于基于绝对的时间同步方法(在第2 段误差开始超过0.125s，后续36段监控已经失效)误差始终在一个合理范围内，提高了监控的准确性。A total of 38 blocks were processed in the test. In the relative time synchronization method based on NC blocks, there are 6 blocks (the vertical dotted line) where the error is cleared when the error exceeds 0.125s at the end of the NC block processing (the vertical dotted line), and 27 blocks. The synchronization error of the entire processing process is less than 0.125s, and the monitoring process does not fail. Compared with the absolute time synchronization method (the error exceeds 0.125s at the beginning of the second segment, and the subsequent 36-segment monitoring has been invalidated), the error is always within a reasonable range, which improves the monitoring accuracy.
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