Design And Implementation Of Tool Working Condition Monitoring System

Machine tool industry, as an important area of advanced manufacturing technology, is developing towards the goal of high efficiency and precision of automated processing. Cutting tool plays a vital role in the cutting process. Abnormal changes in the cutting tool will directly affect the machining accuracy and reliability. Therefore, it is particularly important to develop machine tool working condition monitoring system and monitor tool machining process in real time.In this paper, two intelligent monitoring handles were developed for the real-time monitoring of tool machining process, monitoring vibration signals and cutting force / torque signal respectively.The entire sensor system is integrated inside the handle. Data transmission and power supply are both in wireless way. As for data transmission, by analyzing the signal characteristics of vibration signals and cutting force/torque signals, the function indicators was determined. By designing signal conditioning circuit, data acquisition circuit and wireless communication circuit based on two core microprocessors, hardware platform of the monitoring system were erected. On this basis, signal acquisition, wireless transmission of data and control functions of the system through PC were achieved by building a software platform monitoring system. PC can monitor the waveform of these two tool signals remotely in real time, meanwhile complete the storage of the collected data. As for power transfer, for the structure of machine and handle and the special working conditions ofhigh-speed rotation, electromagnetic resonant wireless power mode was determined. From coil structure and layout in the receiver and the transmitter, handle wireless power supply model of ?2 transmit many receive? was established. For transmitter module, a conversion from DC to high-frequency AC was achieved by designing square wave generating circuit, MOS tube drive circuit and high-frequency inverter circuit. Considering the power requirements of the receiving system and the load equipment, a conversion from high-frequency AC to Multiple DC was achieved by designing rectifier filter circuit and power management circuits to provide DC power to all sensing system inside the handle.On the basis of verifying system equipment performance on each node in data transmission and power transfer, actual functional testing and performance analysis were made for the whole tool monitoring system. These two signals can be monitored remotely in real time through the PC. The viability and stability of the entire tool monitoring system are guaranteed.