Research On On-line Monitoring And Early Warning Of Large Wheel Groove Milling Machine

Nowadays, with the extensive use of the most advanced manufacturing equipment,such as CNC machine tools, CNC machining center, flexible manufacturing system(FMS), manufacturing industry is facing the intelligent direction. At the same time,because of the global manufacturing industry market competition is intense,manufacturers hope the process equipment machine tool have a high reliability, highefficiency and low cost. And equipment condition monitoring and state warning, is themost basic requirements of realizing the intelligent manufacturing, high reliableequipment and low production cost.In order to solve the large wheel groove milling machine failure in the process,improve the reliability of wheel groove milling machine and the machining rotor quality,reduce processing costs, improve production efficiency, this article has carried out thefollowing main contents of the research:Firstly, this article gives each fault an on-line monitoring and state warningsolution, through analyzing the machine, electrical characteristics of large wheel groovemilling of some company and the problem of the rotor indexing asynchronous, spindlecolumn sideslip, milling cutter shatter, combined with the present equipment conditionmonitoring technology research.Secondly, according to the technology which involved in the fault solution, thisarticle has studied signal filtering technology, signal analysis in time domain, frequencydomain analysis, signal wavelet package analysis, multi sensor state recognition anddata compression technology.Then, this article analyzed the fault solutions on the hardware requirements, selectthe appropriate sensor, data acquisition card, the processor, to build the hardware systemsolution for the faults. Also, this article installed and debugged the hardware systems ofthe rotor indexing asynchronous and spindle column slip fault.Finally, this article studied the principle and the programming method ofSiemens840D NC system of the wheel slot milling machine, developed the soft warepart of the rotor indexing synchronization fault monitoring and early warning system.Meanwhile, this article developed a large wheel slot milling cutter wear on-linemonitoring and state warning system, based on the LabVIEW and MATLABprogramming technology.In this paper, the on-line monitoring and early warning subsystem of spindlecolumn sideslip and rotor indexing asynchronous, have been applied in enterprise; theon-line monitoring and early warning subsystem aiming to monitoring the milling cutter “shatter” failure due to serious wear is also applied and verified by practical data fromthe corporate. Therefore, the research has its practical applications.