CNC工具機線上切削異常智能監控與製程優化輔助系統之研究

Development of an On-Line Monitoring Control System for Abnormal Machining and a Machining Process Improvement System

10.6840/cycu201100800

何建鐽

斷刀 ； 刃口積屑 ； 顫振 ； 線上監控 ； 製程優化 ； process optimization ； remote monitoring ； chatter ； cutter breakage ； built-up-edge

中原大學機械工程學系學位論文

2011年

碩士

王世明

繁體中文

本研究目的主要為以訊號處理和診斷技術結合ICT技術發展針對CNC工具機三種常見的切削異常的智能化即時異常診斷與監控和製程優化系統，以得提升加工精度、製程良率及製程優化的目的。所發展的監控系統可對CNC加工發生之切削顫振、刃口積屑與斷刀等異常進行線上即時偵測與抑制，該系統主要包含:（1）近端監控子系統；（2）製程優化輔助子系統。近端監控子系統避免使用計算複雜的訊號轉換分析方法，改採訊號變化特徵分析法及快速傅立葉轉換法來進行訊號分析，針對三種切削異常制定診斷法則，以提高切削異常診斷效率與可靠度；另一方面也利用Fanuc Open CNC Api Spec撰寫程式擷取CNC控制器內的執行中NC碼和機台狀態資訊作為診斷輔助資料以避免誤判，提升系統診斷穩定性。所發展的系統將可在切削顫振、刃口積屑以及斷刀異常發生初期提出早期預警並作抑制控制，以提高機器加工精度及避免機器和刀具壽命的惡化，系統並透過實際切削驗證，顫振可在1秒內診斷出異常情形，並於3秒內抑制異常之情形，而刃口積屑以及斷刀則可在3秒內診斷出異常情形，並於5秒內抑制。此外，研究中也將發展製程優化輔助子系統，利用分析所收集的異常診斷與監控資訊和參數優化演算法，該系統將可建議工程師以提高精度或提高效率為目的的加工參數組合。

By using signal processing and diagnosis technology and ICT technology, the main purpose of this study is to develop an on-line intelligent monitoring and control system of abnormal machining and a machining process improvement system for CNC machine tools. The system can be used to enhance the machining accuracy, improve yield rate of production, and optimize the machining parameters. The system is designed to monitor/control three type of abnormal machining phenomenon: chatter, built-up-edge, and cutter breakage. The system composes two units: (1) on-site monitoring unit; (2) process optimization unit. To increase diagnosis efficiency and reliability, the on-line monitoring system uses signal variation characteristics analysis and Fast Fourier Transfer instead of complex single transfer methods for signal analysis. Besides, Fanuc Open CNC Api Spec is used to develop a program which can on-line extract the instant NC codes and machine state parameters from the CNC controller as reference to avoid fail diagnosis. The system can provide early warning for and control for abnormal machining to improve machining accuracy and protect the machine and cutter. The experimental results have shown that the chatter can be diagnosed within 1 second and suppressed within 3 seconds, and the built-up-edge and cutter breakage can be diagnosed within 3 seconds and controlled within 5 seconds. In addition, though analyzing the monitoring data and computation with process optimizing algorithm the process optimization unit can recommend the machining parameters for better machining efficiency or better machining accuracy.

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