What cutting machines a process is online monitor with from adaptive control

CNC Machining technology is aviation the main component of advanced production technology. As the ceaseless development of aviation industry, aviation manufacturing industry is higher and higher to the requirement of CNC Machining technology. And CNC Machining technology still is existing technical risk and problem, this kind of risk comes from whole treatment process, if equipment element, person is element, workpiece element and cutting tool element,wait. In actual manufacturing process, CNC Machining process is not much axis to be in good position all the time. Cutting force can bring about flexibility to let a knife be out of shape, leftover stress can cause the twist of workpiece to be out of shape, machine tool vibration, cutting tool wears away, the treatment that a variety of elements such as heat in metal cutting also can cause different level is out of shape. The deviation that this makes presence constant between the spare parts that treatment comes out and theoretical model. Once craft parameter choice is unreasonable,be in in treatment process, can bring about workpiece to machine process capability of exterior quality difference, equipment to cannot get sufficient play, the service life that is the same as opportunity bed component and cutting tool also can be affected badly. In machining a process actually, the treatment parameter that uses traditional processing technique to choose is general too conservative, and cannot undertake those who machine a process optimize according to the treatment position with real product. As advanced monitoring technology and the ceaseless development that check an instrument, have the aid of is advanced pass feeling technology, data processing technology and control technology to wait undertake information of geometry of whole process of complex CNC Machining, physics information is gotten, processing, develop a treatment status to decide automatically then with automatism intelligent technology. This kind of technology on one hand compositive the engineering experience with long-term workshop, on the other hand compositive the theoretical model that gets through scientific analysis, undertake judging to machining condition in real time through both union, suit oneself according to what real time operating mode undertakes craft parameter optimize, come true to successive, stable, automatic control machines a process and make its hold best position, achieve taller treatment precision and manufacturing efficiency then, realize treatment process to control thereby from depend on craft to develop to the direction that relies on science. Use what crucial technology faces cutting to machine a process from need of adaptive control technology online or the kind of v/arc be on the throne is right vibration of torque of the cutting force in machining a process, main shaft, machining complex and cutting tool wear away etc undertake real time is monitored, parameter of dynamic analysis, craft is optimized and feedback control. Accordingly, need the support of a variety of technologies from the implementation of adaptive control technology, include sensor technology, signal to handle a technology, be based on confluence of much sensor information technology of decision making techniques of technology, control, database, if the graph is shown 1 times,its concern. 1 sensor technology to make the system can be in complex environment works normally below the medium, condition that intervenes in nobody, must make the system has the information processing capacity that is similar to the mankind, namely intelligence is decision-making. And decision-making need passes intelligence to monitor treatment process to obtain information in real time. Online monitor face treatment process directly, with specific facility and instrument photograph connection. Accordingly, the has sex of high real time, high accuracy and high reliability sensor that applies to treatment process is online monitored key. Basically have with the sensor that monitors at machining a process: Sensor of power sensor, force transducer, torque, sound emissive sensor, oscillatory sensor, photograph like head and laser. (1) power sensor. The machine tool main shaft in machining a process or the power of drive electric machinery can pass power sensor to obtain, the power data that the basis monitors, can rise and fall to what appear in power change, moire, aiguille and short nowadays fall undertake judge and be forecastinged, do flowing processing to power curve through relevant algorithm thereby. In addition, main shaft is effective power is OK the cutting force of token cutting tool, according to the relation of cutting force and main shaft power, the main shaft power that can monitor real time changes the cutting force that is cutting tool, obtain the real time data of cutting force thereby. (2) force transducer. Machine the reliable surveillance of the process to cutting to come true, need cuts the power that place of bits depart process produces to undertake be measured accurately and be analyticed to the metal, spot the defect that in giving cutting course, appears thereby, wear away like cutting tool or rupture, and the injury that processes work. The measurement of cutting force can use direct method or indirect method is measured. In direct measurement technique, sensor installation is in the passageway of force, measure total force, measure very accurate, with the action of force the dot has nothing to do; In indirect measurement method, partial force passes bypass to deliver, because only partial master piece is used on sensor, measure demarcate of the need after power system is installed secondhand, the action point of systematic sensitivity and force is concerned. (3) torque sensor. Opposite at effective power, main shaft torque can the cutting force of well and truly token cutting tool. The torque that measures machine tool main shaft directly can gain more accurate cutting strength. Of bore, tap and process of treatment of much main shaft monitor use the method that measures main shaft torque to gain cutting strength particularly effective. In process of treatment of much main shaft, the power that the cutting process place on each main shaft consumes compares total power small much, accordingly, cannot come with effective power below this kind of circumstance token cutting force, come through main shaft torque however token cutting force. (4) sound launchs sensor. Rupture when cutting tool in cutting process when, can produce transmit. Sound launchs sensor to be able to monitor transmit that arises in cutting process, the signal that monitors through the analysis can obtain the information of cutting tool. Acoustical emissive sensor is small to monitoring the damaged of broach and tap particularly effective. In machining a process sensor can monitor very small transmit, again with effective power or photograph of main shaft torque is united in wedlock, can monitor the damaged of cutting tool reliably. Monitor very small cutting tool and process of treatment of much main shaft in bed of large scale computer especially in, more can dash forward the advantage that shows emissive sensor. (5) oscillatory sensor. Knife, cutting tool is dropped to destroy in cutting process, the vibration with the meeting unusual generation such as mechanical collision. Oscillatory sensor can monitor the vibration that structure of the machine tool in cutting process produces, destroy through analysing vibration to be able to monitor knife, cutting tool, workpiece out of tolerance, mechanical collision and serious process breakdown. Oscillatory sensor also can monitor the vibration of machine tool main shaft, for treatment medium vibration forecasts the process to provide data with control. (6) photograph like the head. In process of treatment of much main shaft, monitor cost of every main shaft respectively taller. Below this kind of circumstance, can use photograph monitor all main shaft like the head. Photograph like the main shaft that the head can monitor 20 or more differs. What can monitor each broach like the head is photograph to drop knife and damaged in much broach treatment. When the system that monitor is learning, record and the image of memory much broach, monitor each broach in the process that monitor through contrasting rough sketch. When the system that is based on other sensor when excel of performance of optics identifying system, it can be used at more processes to monitor, check tool for example, the position, integrality. (7) laser. When cutting when cutting tool is too petty, the wave motion that constant circumstance causes occurrence surprise is smaller, use power sensor, force transducer cannot be monitored, when perhaps installing emissive sensor without proper place, can use laser grating. Laser grating can offer a reliable cutting tool to drop knife and damaged to monitor program. Laser grating also can monitor machine tool heat to be out of shape, the length that monitors machining center main shaft for example is out of shape. Another application of laser is, the ripple of the surface roughness that monitors work through analysing the reflex of workpiece, flutter, cutting. The imitate signal that sensor of 2 signal processing collects in treatment spot is cannot be monitored what the system uses directly, signal of number of need translate into is changed then for practical physical quantity. Transition includes changeover, enlarge, filter commonly wave, flowing etc, this transition needs the technical support that signal handles. General strength, sound blasts off and oscillatory sensor is to press report sensor, need preamplifier changes the charge signal of sensor Cheng Chengzheng is proportional voltage signal. Sound launchs amplifier to obtain primitive signal from sensor, method of the study condition that provides signal, analysis will enhance sound to blast off monitor. Magnify through using, filter and root mean square is average, primitive tone transmit is changed into valuable transmit, can fall in inferior frequency visible and monitor. In addition, oscillatory amplifier can deploy filter and converter of root mean square, can filter insignificant noise obtains oscillatory information. The solution with the commonly used system that monitor is to use the alone signal that designs for specific type sensor to recuperate amplifier. Signature manages implement enclose in an airtight box, join cable is used braid steel net screen to protect, can assure their character that defies vibration and electric segregation so. Accordingly, cable of sensor, join and recuperation implement can processing the work below the environment badly. Because the information confluence that Nextpage3 is based on much sensor machines the diversity of condition of the cutting in the process and cutting position, it is very difficult to bring about pair of cutting processes to undertake accurate monitoring. The traditional measurement that is based on onefold sensor and analysis often assure to identify precision hard. To can obtain the state information that processes a process well and truly, need uses many identical or different sensor to undertake metrical from different respect. Use the complementary sex that different sensor is measured and exports information, use much sensor compositive with information confluence technology, will describe same the condition vector that the conformity of many physical quantity of a treatment system becomes a system, the analysis that is a system and diagnose provide more comprehensive information, make the result that monitor more true, reliable. Method of the most concise confluence of much sensor information is, the measurement of every sensor data inputs shirt-sleeve system alone in, if of every news report that sensor place provides is the completely different respect in the environment, the information that can provide every sensor so changes the different heft that is vector of treatment system condition directly. The main good point of this method is confluence considers a way simple, operation amount is small. If sensor place is offerred environmental information occurrence jackknife, and the redundant, contradiction of likelihood occurrence information and, appear even the work that among them a certain sensor affects other sensor, the information that comes from different sensor must be in a variety of expression undertake confluence on administrative levels, obtain the condition vector that processes a system finally. Below this kind of circumstance, confluence of much sensor information can obtain more accurate state information. Confluence of much sensor information basically has the advantage of the following respects: Increased the reliability of information, dimension that added systematic condition vector, fault tolerance capacity that increased a system. After the 4 condition news that dominated decision-making control system to acquire treatment system, integration analysis processes the data that monitors in the process, temperature of force of the vibration in getting treatment course, cutting, cutting, cutting tool wears away, treatment is out of shape wait for data, with good treatment condition contrasts. Will actual condition and good position information give processing of in-house expert system, the inferential machine of expert system reads the experience data in taking a knowledge base and the news that machine systematic oneself, the moving position that the state information that analyses treatment system will come to judge treatment system is good. Run vibration of condition and cutting parameter and treatment process according to processing a system, be out of shape wait for the relation between the element to choose optimize regulation, trends optimizes craft parameter to make machine a system to achieve more the moving condition of actor. Realize speed of rotate speed of pair of machine tool main shaft, feed to wait for cutting parameter through the interface between controller hardware and system of machine tool NC optimize control. If the graph is shown 2 times,the expert fastens the principle of all. The craft parameter library that 5 databases technology is based on database technology basically includes cooling and material of machine tool, cutting tool, workpiece, lubricant, treatment to match, the information such as parameter of spare parts feature, cutting, moving condition, among them cooling and material of machine tool, cutting tool, workpiece, lubricant, treatment matchs, spare parts feature gave out the basic message of machining complex, cutting parameter, moving condition described what machining complex falls in different technology parameter to run condition message. Craft parameter library is the gathers for a long time experience data in project practice, have actual application value, what can be expert system is decision-making provide engineering experience. Expert department is material of all general machine tool, cutting tool, workpiece, cooling lubricant, treatment matchs, the matchs a relation to be optimized as parameter regulation of the machining complex information such as spare parts feature and cutting parameter, moving condition, with machining complex current moving condition is basic fact, the experience data in model of theory of basis treatment process and craft parameter library undertakes deduction inference, get the system optimizes parameter currently finally. The database system of machine of expert system inference is shown 3 times like the graph. Already had product and applied current situation in recent years, monitor domestic and internationally in the light of what machine a process work with the research that made medium application begin disparate arrangement of ideas in aviation engine from adaptive control technology, typical trade includes OMATIVE to be mixed from cutting tool of adaptive control system, ARTIS with the system cutting tool of supervisory system of processing supervisory system, monitoring of BRANKAMP-CNC compositive cutting tool, MonTRONIX, NORDMANN is monitored control a system to wait with the process, if the main sensor that place of this kind of supervisory system uses expresses 1 to show. Nextpage1 OMATIVE gets used to a system to will apply on numerical control machine tool from adaptive control technology oneself from OMATIVE of adaptive control system, optimize the feed speed of cutting in real time according to cutting force in machining a process, treatment efficiency improves below the premise that makes sure cutting tool is not damaged bad. OMATIVE gets used to a system oneself main function: Improve treatment efficiency; Protective cutting tool, machine tool, workpiece is not damaged kill; Cutting of real time monitoring, record machines a state. The relation of speed of cutting tool feed and cutting ply is shown 4 times like the graph. Israel OMATIVE company did test of contrast of much work cutting, OMATIVE gets used to a system to be able to improve treatment efficiency considerably oneself. OMATIVE from adaptive control system because its are practical the effect is distinct, now already by abroad a lot of well-known companies are used, wait like Siemens, Boeing and General Electric. The well-known company of the industry such as domestic aerospace, spin, home appliance also uses this product in succession. 2 ARTIS cutting tool and monitoring of cutting tool of ARTIS of processing supervisory system and supervisory system of machine tool state are by the real time of research and development of German ARTIS company online supervisory system. In machining a process, can detect well and truly knife, blunt knife reachs knife state. Once appear unusual situation, the machine tool stops immediately machine, avoid what cutting tool, workpiece reachs a machine tool to be injured again. Use all sorts of sensor of ARTIS, can undertake monitoring to treatment and machine tool state. Use different monitoring kind to still can specific aim ground brings more profit for the user, be like those who use ARTIS from adaptive control, not only can undertake monitoring to cutting tool and machine tool state, still can be opposite at the same time treatment cycle undertakes optimizing, improve the treatment efficiency of the machine tool effectively. Supervisory system of BRANKAMP of monitoring of 3 BRANKAMP-CNC compositive cutting tool protects facility according to the specific limit that monitor, the configuration of any irregular force is monitored to come out on metropolis horse, it is any the smallest errors even, before causing main harm, this system that monitor discovers instantly and make response, if pursue,5 are shown. BRANKAMP supervisory system offers a process to monitor for the production process such as all metallic cut, punch, cold forging. BRANKAMP basically serves an object to include cut of punch, cold processing, metal to wait for treatment facilities, main application is made at the car industry, close industry of treatment of manufacturing industry of a treatment industry, mobile phone, semiconductor, food and beverage metal are packed wait for industry domain. Installation BRANKAMP monitors a system to be able to protect mechanical equipment and costly mould, reduce reject and equipment maintenance time, managing cost, improve product quality, have online monitoring and visible result function at the same time. 4 MonTRONIX cutting tool and cutting tool of MonTRONIX of process supervisory system and process supervisory system use sensor of one or more pressure, torque, oscillatory, power and a processor, obtain real time the monitoring data about cutting cutting tool, machine tool and treatment process. Workpiece of clamping apparatus of the machine tool that this supervisory system can give production system, cutting tool, tool, treatment provide protection, control the treatment quality of workpiece strictly, raise the safety that machines a process and dependability, reduce finished cost. The visible software of form a complete set (M-View) make machine handlers can evaluate treatment course accurately. Its graph changes show include: Process deviation, cutting tool attaint, the wear extent that increases gradually, the system can undertake record and be assessmented to these information. This system is machining any moment in the process to undertake visible show. 5 NORDMANN cutting tool monitors the solution that controls systematic NORDMANN with the process to be able to be opposite the cutting tool damaged in machining a process, wear away undertake detecting, to colliding load of interference, cutting tool balances condition to undertake monitoring, undertake protective to cutting tool and machine tool thereby. In addition, this system is OK still the size of work semifinished product that holds calorie of condition, mistake correctly to the blame of workpiece undertake detecting and final to workpiece inside the machine tool figure has size control, assure the treatment quality of the product thereby. Machining efficiency respect, NORDMANN supervisory system can pass indirect way to wait to force of the effective power in metallic cutting process, cutting undertake controlling, can decrease to cut time for nothing thereby, lengthen cutting tool the service life, biggest change feed and rotate speed to machine efficiency in order to rise. The NORDMANN system that monitor can expand following and additional measurement system: The phonic dimension that force transducer, sound launchs power of sensor, have rendered great service to measure measuring implement, workpiece is monitored, the sensor that optical laser sensor, direct installation cuts a share at cutting tool (graph 6) . In monitoring process, this system can be generated in real time measure data and show the operation face plate in PCU50/PCU70 module to go up, can be opposite of cutting tool wear away, the condition such as damaged undertakes assessment. On applied limits, of the physical quantity such as the power that NORDMANN supervisory system can use in the equipment treatment process such as CNC lathe, machining center, grinder, force, torque monitor with control. What last word cutting machines a process is online monitor already applied extensively in abroad with control system, obtained remarkable result. But, this kind of system did not get applied extensively in home. Enlist in army as the wide application of complex structure product, product the ceaseless promotion that function asks to product treatment quality, and manufacturing company is efficient to product low cost the ceaseless pursuit of treatment, use corresponding monitoring and optimize a system to machine a process to undertake online monitoring keeps abreast of to cutting of travel cutting parameter online optimize the focal point that already made research of intelligent processing technique and project application gradually, will machine the development of demand as CNC Machining technology and complex product and get applied extensively. CNC Milling