Research On The Drilling&Dimpling Tool Monitoring Based On Power Signal And Its System Development

In the field of machinery manufacturing,the state of cutting tool directly affects the quality and efficiency of machining.Therefore,the significance of tool conditional monitoring is very important.The monitoring equipment determines tool condition by the power threshold in the production line of flexible manufacturing system and computer integrated manufacturing system.In actual machining,if the cutting parameters change,we should reset the threshold parameters for each procedure,and can not be applied to the variable cutting process.The conventional spindle power threshold comparison method used in traditional tool condition monitoring has the power feedback delay,which can not adapt to the changeable working condition of the cutting process well.The background of this paper is base on the digital assembly system of aircraft wing box developed by the aircraft digital assembly team from zhejiang university.In view of the existing problems of tool condition monitoring equipment used in the project,put forward monitoring method and improvement measure.Using the real-time spindle speed,feed speed and power,current and torque signal in CNC machines as system input,after signal preprocessing and characteristic parameter extraction,establishing the model between cutting parameters and processing power,then achieve the identification of wearing tools,overload protection,automatic withdrawal and automatic tool change,tool warehouse management and so on.The SINUMERIK Operate Package was used to develop Siemens 840Dsl operating system,completed the design of tool condition monitoring systems(TCMS)and integration in the numerical control system.The research works carried out in this paper are as follows:(1)This paper studies the signals used in tool state monitoring,and analyzes the advantages and disadvantages of power,cutting force,vibration and AE signal.At the same time,the basic monitoring principle of tool monitoring equipment used in this project is studied.Based on this,the research contents and objectives of this paper are proposed.(2)Analyzed the process and characteristics of drilling&dimpling end-effector.According to the current situation of tool state monitoring TMAC adaptive controller can not be effectively monitored in the monitoring process,the specific solution is put forward and the experiment and design are carried out.(3)Based on the power threshold monitoring,the model between power and processing parameters is established by using adaptive neural fuzzy system and support vector regression.Use the model to update the threshold in real time and then compared with the actual cutting power,determine the state of the drilling tools and execute the strategy of tool change.(4)Using the API component of SINUMERIK Operating Package for the development of tool state monitoring system,the development environment is Visual Studio 2008 and Qt class library,realized the functions of tool on-line monitoring,overload protection,automatic withdrawal and automatic tool change,tool warehouse management and so on.At the same time,using MATLAB COM module and LIBSVM for data processing,the research and development of tool state monitoring system(TCMS)and HMI design were completed.Finally,the development of tool condition monitoring system(TCMS)was completed in the Sinumerik 840Dsl,the idea's application in actually project was certified.