现代制造设备维修监测策略及再制造技术

对机械制造过程中设备维修检测策略进行了论述,其内容包括：建立与设备技术特性相适应的监测诊断体系统;提高监测维修人员业务素质;建设与单位设备、财力相适应的维修检测环境和硬件平台;综合运用各种先进检测与诊断技术。对先进表面工程、先进加工技术、数字控制技术在机床再制造中的应用进行了介绍。为机械制造企业建立具有本单位特色的设备监测维修体制和设备再制造工程提供了参考。     

An overview of approaches to end milling tool monitoring

The increase in awareness regarding the need to optimise manufacturing process efficiency has led to a great deal of research aimed at machine tool condition monitoring. This paper considers the application of condition monitoring techniques to the detection of cutting tool wear and breakage during the milling process. Established approaches to the problem are considered and their application to the next generation of monitoring systems is discussed. Two approaches are identified as being key to the industrial application of operational tool monitoring systems.Multiple sensor systems, which use a wide range of sensors with an increasing level of intelligence, are seen as providing long-term benefits, particularly in the field of tool wear monitoring. Such systems are being developed by a number of researchers in this area. The second approach integrates the control signals used by the machine controller into a process monitoring system which is capable of detecting tool breakage. Initial findings mainly under laboratory conditions, indicate that both these approaches can be of major benefit. It is finally argued that a combination of these approaches will ultimately lead to robust systems which can operate in an industrial environment.     

Automated energy monitoring of machine tools

Reducing the energy consumption of machine tools can significantly improve the environmental performance of manufacturing systems. To achieve this, monitoring of energy consumption patterns in the systems is required. It is vital in these studies to correlate energy usage with the operations being performed in the manufacturing system. However, this can be challenging due to complexity of manufacturing systems and the vast number of data sources. Event stream processing techniques are applied to automate the monitoring and analysis of energy consumption in manufacturing systems. Methods to reduce usage based on the specific patterns discerned are discussed.     

Workpiece and Tool Handling in Metal Cutting Machines

Recently many researchers have focused substantial efforts on understanding the cutting process in mechanics, capability and design. Advances in machine performance with research towards high performance cutting (HPC) and high speed cutting (HSC) have led to improved tool properties and application of advanced materials. Because of that, primary processing time has been successfully reduced, which leads to the need for re-focusing on reduction of secondary processing time. Minimizing the time for workpiece and tool changing, re-positioning, workpiece handling, and tool handling systems shift attention towards improvement of these systems which are currently installed in various metal cutting machine tools. This paper presents an approach for the assessment of the technological effectiveness of workpiece and tool handling systems for metal cutting machine tools, gives an overview of the state of the art of these systems, surveys recent developments and elaborates requirements for future systems.     

数控机床高精度感应同步器的调整方法

本文通过某型号加工中心434#报警的处理，对数控机床上的重要检测元件-感应同步器的安装与调整做了较深入的研究和探索，总结出一套适合于全闭环数控机床感应同步器的安装与调整的快速有效的实用方法。     

Compact design for high precision machine tools

Due to raising functional integration in micro fluidic, micro mechanic, micro electronic and micro optical systems the trend to scaling down the work piece sizes while increasing its complexity requires high precise machine accuracy. With respect to the process and geometrical parameters, most of the finishing manufacturing processes can be covered by milling and grinding operations with three or five machine axes. But whereas the available machine tools hardly achieve the required process dynamic and accuracy in all degrees of freedom, the requirements still increase. For this reason the Fraunhofer IPT has developed high precise machine tools following a compact design strategy by reducing the overall machine dimensions as far as conventional machine components such as measuring or drive systems were available. The developments of two compact machine tools exemplify the dynamic and accuracy enhancement by compact design and are described in the following.     

A review of the evolution of microcontroller-based machine and process monitoring

This paper reviews the evolution of intelligent, distributed, microcontroller based machine and process monitoring systems. It considers basic building blocks that support such systems through the development of fault diagnostic methods, intelligent system based approaches and sensor-based machine monitoring. It then identifies three approaches that may be utilised when designing monitoring system architecture: integrated, distributed and embedded. Current applications of these approaches, when deployed individually and in combination with each other, are then discussed. In particular, the paper considers the efficacy of microcontroller based embodiments, in both current and future monitoring activities.     

Sensor-less Monitoring of Cutting Force during Ultraprecision Machining

Future ultraprecision machining systems will require intelligent machine tools equipped with effective systems for in-process monitoring of maching status. To meet the requirement, much attention has been directed to the monitoring method of cutting force, temperature, acoustic emission, etc. Cutting force includes useful information on machining status, however, it is difficult to apply these methods for an ultraprecision maching environment. In this paper, a sensor-less monitoring method has been proposed based on a new concept. In the proposed method, a disturbance observer is installed In the position controller for a liner motor-driven aerostatic table system. The performance of the monitoring system has been evaluated through a series of ultraprecision machining experiments.     

Design of dynamic multi sensor systems

Recent increase in machine automation, machine capability, and the performance of machining processes lead to high demands on process monitoring systems. In the Center of Production Engineering in Hannover Gentelligent^® manufacturing systems are researched, which will be able to meet those requirements. One enabling factor for these systems is the “feeling” capability, achieved by multi sensor systems. This paper copes with the design of these systems. This includes on the one hand the development of sensor configurations and on the other hand a concept for sensor fusion. For the search of optimum sensor configurations a previously developed algorithm is extended to consider the dynamic behavior of the sensor systems.     

Sensorless automated condition monitoring for the control of the predictive maintenance of machine tools

Modern manufacturing systems are characterized by numerous interacting machine tools each with sophisticated maintenance. In order to be competitive, it is possible to reduce the system downtime by applying sensorless automated condition monitoring (SACM). This paper presents newly developed and tested SACM-algorithms based only on signals which are available in position controlled drives such as position, speed and motor current. The algorithm is based on comparing current characteristic parameters with those which were taken when the machine was new.     

面向加工程序优化的铣削过程模拟技术

针对CAD/CAM系统不能自动生成加工参数的问题,国内外许多学者提出了利用加工过程模拟技术加工程序的思想,随着对切削机理认识的不断加深和计算机仿真技术的发展,铣削加工模拟优化系统得到了大量的研究和开发。对铣削过程模拟中的两个关键技术-几何模拟技术和物理模拟技术进行了归纳和分析。     

可重用电火花线切割机仿真系统的研究

研究了一种可重用的电火花线切割机的仿真系统，能用于各种线切割机的数控系统和自动编程系统中，能接受不同机床、不同形式的数控代码，对数控代码进行语法检查及零件尺寸、位置、加工行程等校验，最后形成三维真实感零件和动态加工过程。重点对零件加工过程动态仿真的实现进行了探讨。     

Prediction of the dynamic behaviour of machine tools during the design process using mechatronic simulation models based on finite element analysis

Increased productivity, higher velocities and acceleration for feed and cutting motions are requirements for innovative machine tools. At the same time the production process must achieve reduced form and position deviations of the work-piece. Therefore knowledge of the dynamic behaviour of machine tools during the design process is essential to develop high-performance machines. Using finite element analysis and mechatronic simulation, taking the mechanical, electrical and control systems into account, is the first step for optimisation. Developing the control parameters using these simulation techniques is one of the major steps in detecting the mechatronic characteristics. This paper presents a method for developing the control parameters concerning tool to work-piece deviations of mechatronic simulation models including disturbance variables. As an example a 2-axis CNC test stand for feed drive axes will be visualised with its simulation and measurement results in the time and the frequency domain.     

Online adaption of milling parameters for a stable and productive process

On the way to fully autonomous machine tools it is essential to independently select suitable process parameters and adapt them on-the-fly to the appropriate process conditions in a self-controlled manner. Such systems require complex physical process models and are usually limited to feed and spindle speed adaption during the milling process. This paper introduces a new approach enabling machines during the milling process to learn which parameters lead to a stable process with maximum productivity and to adjust them autonomously. It is shown that this approach enables the machine tool to independently find stable process parameters with maximum productivity.     

基于5G通信的数控机床智能监控与诊断系统设计

针对目前数控机床智能监控水平较低、智能化不足的问题,提出基于5G通信的数控机床智能监控与故障诊断系统。该系统以高性能STM32为硬件核心,搭载AliOS Things嵌入式操作系统实现机床电机工作电流、电压、温度和振动信号的实时监测;再提取信号时频域特征,进行故障状态识别,通过5G通信智能网关将异常状态数据上传到远程智能监控服务平台。该平台还能下发指令给监控系统,提示并辅助工作人员对存在故障风险的数控机床进行及时维护。经测试,该系统能够实现高并发海量数据的采集与高速传输,5G通信传输速度在500 Mb/s,传输时延在20 ms以内,平均数据丢包率在2%内。测试结果表明该系统性能稳定可靠,在满足数控机床智能监控同时,为数控机床设备的智能升级提供技术方案。     

Condition monitoring of monorail guidance systems

Reliable machine tools play a crucial role in the productivity of industrial facilities. In spite of high-quality machines, unscheduled downtimes are often caused by damaged machine components. A new diagnosis tool for machine components is outlined in this paper, with the main focus on monorail guidance systems. Based on sensor signals and information from the machine control system, the method enables the condition of the monorail guidance system to be evaluated in a simplified way. Typical types of damage and the diagnosis tool that has been developed are presented. The way in which the diagnosis tool may be used for detecting different types of damage is described. Using the condition monitoring method, it should be possible to estimate the service limit of the monorail guidance system.     

数控机床伺服进给系统状态监测方案的分析比较

为了得到准确获取机床状态监测信号的方法,研究了机床状态信号获取的3种方案,即外置传感器信号、内置传感器信号和伺服驱动器监测端口信号。这3种信号都是可靠的信息来源,但是信号获取的难度和信号质量各有优劣。分析比较了这3种方案,分析结果对研究数控机床伺服进给系统在线监测技术、提高机床可靠性和加工质量具有参考意义。