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CN101984376B - Fault simulation device of numerical control machine - Google Patents

Fault simulation device of numerical control machine Download PDF

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Publication number
CN101984376B
CN101984376B CN 201010550163 CN201010550163A CN101984376B CN 101984376 B CN101984376 B CN 101984376B CN 201010550163 CN201010550163 CN 201010550163 CN 201010550163 A CN201010550163 A CN 201010550163A CN 101984376 B CN101984376 B CN 101984376B
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machine tool
fault
module
simulation device
cnc
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CN101984376A (en
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唐小琦
周会成
任清荣
陈吉红
宋宝
汤明
孙东山
奚长浩
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Huazhong University of Science and Technology
Wuhan Huazhong Numerical Control Co Ltd
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Huazhong University of Science and Technology
Wuhan Huazhong Numerical Control Co Ltd
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Abstract

本发明涉及一种数控机床故障模拟装置，该装置采用现场总线与数控装置相连，内部采用上下位机结构。下位机为采用Linux实时操作系统的工控机，主要负责运行数控机床的PLC逻辑模型，并通过现场总线与数控装置进行数据交换；上位机则采用运行WINDOWS操作系统的PC机，通过通用以太网与下位机相连，主要解决数控机床参数设置、故障设置、故障报警等人机交互工作。本装置主要解决高档数控装置的故障检测功能和能力的试验条件，可以模拟数控机床故障、可编程控制器故障、伺服驱动器和伺服电机故障、主轴驱动器和主轴电机故障。利用该装置模拟数控机床的故障可以用来检测数控装置对数控机床故障的响应、保护、自动修复等能力。

Figure 201010550163

The invention relates to a fault simulation device for a numerically controlled machine tool, which is connected with the numerically controlled device by using a field bus, and adopts an upper and lower computer structure inside. The lower computer is an industrial computer using the Linux real-time operating system, which is mainly responsible for running the PLC logic model of the CNC machine tool, and exchanging data with the numerical control device through the field bus; the upper computer uses a PC running the WINDOWS operating system, and communicates with The lower computer is connected, which mainly solves the human-computer interaction work such as CNC machine tool parameter setting, fault setting, and fault alarm. This device mainly solves the test conditions of the fault detection function and capability of high-grade CNC devices, and can simulate faults of CNC machine tools, programmable controllers, servo drives and servo motors, spindle drives and spindle motors. Using the device to simulate the failure of the CNC machine tool can be used to test the ability of the CNC device to respond to the failure of the CNC machine tool, protect it, and automatically repair it.

Figure 201010550163

Description

A kind of fault of numerical control machine tool analogue means
Technical field
The invention belongs to the numerical control device testing apparatus, be specifically related to a kind of fault of numerical control machine tool analogue means.
Background technology
In the links such as testing and training of numerical control device, numerical control device need and be controlled electric cabinet and use with lathe, and this mode not only cost is high, and very inconvenient.This fault simulation device mainly solves the fault detection capability and the ability of high-grade numerical control device, can simulate fault of numerical control machine tool, Programmable Logic Controller fault, servo-driver and servomotor fault, spindle driver and spindle motor fault.Utilize the fault of this device simulation numerically-controlled machine can be used for detecting numerical control device to the response of fault of numerical control machine tool, protection, ability such as reparation automatically.
The manufacturer of some numerical control devices is according to self product characteristic at present, and the fault simulation device of exploitation has very strong specificity.Because the configuration of the different model numerically-controlled machine that different manufacturers is produced is all inequality, its fault that need simulate is also different, so these special-purpose fault simulation devices can not be simulated the various faults of various lathes easily.Do not have the comprehensive of versatility and fault simulation.
Summary of the invention
The invention provides a kind of fault of numerical control machine tool analogue means; This device adopts fieldbus to link to each other with numerical control device; The inner upper and lower computer structure that adopts; Slave computer mainly is responsible for the PLC logical model of operation numerically-controlled machine for adopting the industrial computer of Linux real time operating system, and carries out exchanges data through fieldbus and numerical control device; Host computer then adopts the PC of operation WINDOWS operating system, links to each other with slave computer through general Ethernet, mainly solves man-machine interaction work such as the setting of numerically-controlled machine parameter, fault setting, fault alarm.
This fault simulation device mainly by numerically-controlled machine module is set, fault is provided with module, logical operation module, servo computing module, he lathe operation display module, communication module is formed.
Lathe is provided with module, is used for the user different machine tool type (like lathe, milling machine, machining center etc.) is set, and selects the corresponding number of axle and structure, imports corresponding fault database according to machine tool type; Show corresponding lathe IO state, dispose corresponding lathe PLC logical model and servo drive system model; At last all settings are saved as a specific lathe model.The man-machine interface that lathe is arranged on the PC is carried out, and the lathe model sends slave computer to through network.
Fault is provided with module, is used for the fault that the user is provided with the needs simulation, as importing phase shortage, brownout etc. in the electric loop.All selection is provided with fault after the user is provided with machine tool type, is written into the fault database file automatically, and the user sets fault and preserves with fault data, and send slave computer to through network after the selected fault that is provided with.
Logical operation module; According to lathe the set different lathe models of module are set; Logical operation module is accepted the I/O information that numerical control device sends, and with these information as input, according to the PLC logical relation of numerically-controlled machine; Calculate the I/O information that feeds back to numerical control device, the postrun state of simulated machine tool control circuit.
Servo computing module, the lathe servo-drive and the transmission link of consideration perfect condition call the module library of modeling and simulating instrument three ring (position ring, speed ring, electric current loop) PID controls and the lathe gear train of servo-drive system are set up the transport function realistic model.The ideal model that passes through to be built is realized the dynamic simulation of servo drive system and lathe gear train, and through bus the data that servo module three encircles is fed back to numerical control device.
Lathe running status display module is used to simulate the state of display machines bed operating, like positional information, and tool-information, switch board I/O dot information, failure message.Wherein positional information shows with position data, and tool-information shows cutter number and subsidiary function, and control circuit I/O dot information shows that with Dynamic Button failure message can show fault picture and Word message.
Communication module, communication module comprise that slave computer is connected and data communication the TCP/IP server end between slave computer and the host computer, the TCP/IP client of host computer with bus between the numerical control device.
What the fault simulation device was identical with actual lathe is; This system has the physical interface that can receive the numerical control device instruction and feed back the numerical control device desired data; This data exchange interface can be a node of digital control system on-the-spot bus, also can be signals collecting interface open in the whole digital control system control loop.Different with actual lathe is, this system is the realistic model of the data and the logic of an actual lathe, according to machine tool type through bug list being set and machine tool type and I/O point, the various faults of coming simulated machine tool being set.
Description of drawings
Fig. 1 is a functional module graph of a relation of the present invention;
Fig. 2 is a hardware configuration graph of a relation of the present invention;
Fig. 3 is a software configuration graph of a relation of the present invention;
Fig. 4 is embodiment figure of the present invention;
Fig. 5 is fault simulation running software of the present invention interface;
Fig. 6 is a lathe modeling software runnable interface of the present invention.
Embodiment
Structural relation synoptic diagram between each functional module of inside of a kind of fault of numerical control machine tool analogue means that designs for the present invention shown in Figure 1.Comprise that lathe is provided with module, fault is provided with module, logical operation module, servo computing module, lathe operation display module, communication module.
The task division of each intermodule is following:
Lathe is provided with module, is used for the user different machine tool type (like lathe, milling machine, machining center etc.) is set, and selects the corresponding number of axle and structure, imports corresponding fault database according to machine tool type; Show corresponding lathe IO state, dispose corresponding lathe PLC logical model and servo drive system model; At last all settings are saved as a specific lathe model.The man-machine interface that lathe is arranged on the PC is carried out.
, the user selects corresponding lathe setting in being provided with; In fault setting option being set in the hurdle changes accordingly; As lathe all have electric loop, axis system, feed system, cooling system, guard system etc., then also have tool magazine and tool changing device etc. for machining center.
In the user is provided with, select corresponding lathe setting, conversion is shown the state that different systems and I/O are ordered at lathe running status display panel.
In case lathe set to be accomplished, will form the model of a specific lathe at last, comprise lathe type, structure, logical model, fault, show state can be set.The lathe model sends slave computer to through network.
Fault is provided with module, is used for the fault that the user is provided with the needs simulation, as importing phase shortage, brownout etc. in the electric loop.All selection is provided with fault after the user is provided with machine tool type, is written into the fault database file automatically, and fault database comprises can be provided with fault, phenomenon of the failure and fault possible cause.The user sets fault and preserves with fault data, and send slave computer to through network after the selected fault that is provided with.
After fault is provided with, will triggers refreshing of status panel according to the I/O state of slave computer computing at lathe running status display panel, and can show the simulation picture of fault.
The hardware configuration graph of a relation of a kind of fault of numerical control machine tool analogue means that designs for the present invention shown in Figure 2.The fault simulation device is made up of host computer and slave computer.Host computer adopts PC and general Ethernet, operation Windows operating system.Slave computer adopts the industrial computer with general Ethernet, links to each other the operation (SuSE) Linux OS with fieldbus slave station card through parallel bus.Slave computer docks with numerical control device through fieldbus main website card, and is interconnected through Ethernet and host computer.
The software configuration graph of a relation of a kind of fault of numerical control machine tool analogue means that designs for the present invention shown in Figure 3.Host computer is written into and work such as test result output with demonstration, configuration, the model of operation man-machine interface.Therefore host computer moves 2 process modules, FaultSim, Plcad.
FaultSim fault simulation module is used for the test of numerical control device in the fault function aspects, and this module is responsible for that the lathe logical model is written into, the demonstration of the setting of fault project and test result, and is as shown in Figure 4.The Plcad module mainly is used for the logical model of lathe is carried out modeling, and modeling can be adopted ladder diagram and C language, and is as shown in Figure 5.
Slave computer carries out the collection, computing of data, feedback and communicating by letter with host computer in real time.Main operation logic simulation process RunPLC of slave computer and communication module process.Logic simulation process RunPLC moves the logical model * .plg that Plcad generates above that, and the corresponding different logical model of different lathes can be created corresponding lathe logical model according to the Machine Tools Electric schematic diagram of test.The logic simulation process is according to the I/O data of bus input, through the feedback data of lathe PLC logical model computing I/O.Its part feedback sends it back numerical control device through bus, and another part sends to host computer and shows.
The communication module process comprises two parts, and a part is from fieldbus slave station card buffer reading of data and inserts feedback data that this part real-time is higher; Another part is for sending data and accept configuration and steering order to host computer through Socket (ICP/IP protocol), and this part real-time requires lower, is mainly used in demonstration, emulation, mutual with the operator.
It should be noted last that; Above embodiment is only unrestricted in order to technical scheme of the present invention to be described; Although with reference to preferred embodiment the present invention is specified, those of ordinary skill in the art should be appreciated that and can make amendment or be equal to replacement technical scheme of the present invention; And not breaking away from the spirit and the scope of technical scheme of the present invention, it all should be encompassed in the middle of the claim scope of the present invention.

Claims (6)

1.一种数控机床故障模拟装置，该模拟装置采用现场总线与数控装置相连，内部采用上下位机结构，下位机为采用Linux实时操作系统的工控机，主要负责跟数控装置进行总线数据交换和运行逻辑模型；上位机为采用WINDOWS操作系统的PC机，通过以太网网络与下位机相连，主要解决机床参数设置、故障设置、故障报警人机交互的工作；1. A kind of numerical control machine tool failure simulation device, this simulation device adopts fieldbus to be connected with numerical control device, adopts upper and lower computer structure internally, and lower computer is the industrial computer that adopts Linux real-time operating system, is mainly responsible for carrying out bus data exchange with numerical control device and Run the logic model; the upper computer is a PC using the WINDOWS operating system, which is connected to the lower computer through the Ethernet network, and mainly solves the work of machine tool parameter setting, fault setting, and fault alarm human-computer interaction; 该数控机床故障模拟装置主要由机床设置模块、故障设置模块、逻辑运算模块、伺服运算模块，机床运行显示模块、通信模块组成；The CNC machine tool fault simulation device is mainly composed of a machine tool setting module, a fault setting module, a logic operation module, a servo operation module, a machine tool operation display module, and a communication module; 所述的机床设置模块，根据所选择的模拟机床类型，对该模拟机床的各个参数进行相应的设置；通过对不同模块参数的设置，使得所述的数控机床故障模拟装置能够模拟数控车床、数控铣床、加工中心，能满足对不同厂商生产的数控机床的模拟，增强了该模拟装置的通用性；Described machine tool setting module, according to the selected simulated machine tool type, each parameter of this simulated machine tool is set correspondingly; Through the setting of different module parameters, make described numerically controlled machine tool fault simulation device be able to simulate numerically controlled lathe, numerically controlled Milling machines and machining centers can satisfy the simulation of CNC machine tools produced by different manufacturers, which enhances the versatility of the simulation device; 所述的故障设置模块，根据所选择的模拟机床类型，对该模拟机床的各种故障进行相应的设置；通过在故障设置模块中选择不同的故障设置，使得所述的数控机床故障模拟装置能够模拟机床的电源回路缺相、编码器接触不良、伺服强电断开的故障，能满足用户模拟各种不同故障的需求，增强了该模拟装置的通用性。The fault setting module, according to the selected type of simulated machine tool, correspondingly sets various faults of the simulated machine tool; by selecting different fault settings in the fault setting module, the described CNC machine tool fault simulation device can Simulating the faults of the power circuit of the machine tool, such as lack of phase, poor contact of the encoder, and disconnection of the servo power, can meet the needs of users to simulate various faults, and enhance the versatility of the simulation device. 2.根据权利要求1所述的数控机床故障模拟装置，其特征包括：该数控机床故障模拟装置通过数控系统现场总线从站卡来接收数控装置发送的指令和数据；得到的数据经过数控机床故障模拟装置分析处理后，一方面给数控装置反馈数据，一方面发往上位机中进行人机交互；模拟软件根据机床设置模块和故障设置模块确定的模型计算出反馈数据；该数控机床故障模拟装置内部的逻辑运算模块用来模拟IO响应、伺服运算模块用来模拟伺服驱动和机床的加工特性。2. The numerically controlled machine tool failure simulation device according to claim 1, characterized in that it comprises: the numerically controlled machine tool failure simulator receives instructions and data sent by the numerical control device through the numerical control system field bus slave station card; the data obtained passes through the numerically controlled machine tool failure After the analysis and processing of the simulation device, on the one hand, the data is fed back to the CNC device, and on the other hand, it is sent to the upper computer for human-computer interaction; the simulation software calculates the feedback data according to the model determined by the machine tool setting module and the fault setting module; the CNC machine tool fault simulation device The internal logic operation module is used to simulate the IO response, and the servo operation module is used to simulate the processing characteristics of the servo drive and the machine tool. 3.根据权利要求1所述的数控机床故障模拟装置，其特征在于所述的逻辑运算模块，逻辑运算模块能够根据不同的逻辑模型来运算获得IO反馈结果；逻辑模型可采用梯形图或C语言来实现。3. The numerically controlled machine tool fault simulation device according to claim 1, is characterized in that described logic operation module, logic operation module can calculate and obtain IO feedback result according to different logic models; Logic model can adopt ladder diagram or C language to fulfill. 4.根据权利要求1所述的数控机床故障模拟装置，其特征在于所述的伺服运算模块，考虑理想状态的机床伺服驱动和传动环节，调用建模仿真工具的模块库对伺服系统的位置环、速度环、电流环PID控制和机床传动机构建立传递函数仿真模型；通过所建的理想模型来实现伺服驱动系统和机床传动机构的动态仿真，并通过总线反馈位置环、速度环、电流环的数据回数控装置。4. CNC machine tool failure simulation device according to claim 1, is characterized in that described servo operation module, considers the machine tool servo drive of ideal state and the transmission link, calls the module storehouse of modeling simulation tool to the position loop of servo system , speed loop, current loop PID control and machine tool transmission mechanism to establish a transfer function simulation model; realize the dynamic simulation of the servo drive system and machine tool transmission mechanism through the ideal model, and feedback the position loop, speed loop, and current loop through the bus The data is returned to the CNC device. 5.根据权利要求1所述的数控机床故障模拟装置，其特征在于所述的机床运行显示模块，用于模拟显示机床运行状态的位置信息，刀具信息，控制柜IO点信息，故障信息；其中位置信息以位置数据显示，刀具信息显示刀号和辅助功能，控制柜IO点信息以动态按钮显示，故障信息可显示故障画面和文字信息。5. CNC machine tool fault simulation device according to claim 1, is characterized in that described machine tool operation display module, is used to simulate the position information of display machine tool operating state, cutter information, control cabinet IO point information, fault information; Wherein The position information is displayed by position data, the tool information displays the tool number and auxiliary functions, the IO point information of the control cabinet is displayed by dynamic buttons, and the fault information can display fault screen and text information. 6.根据权利要求1所述的数控机床故障模拟装置，其特征在于所述的通信模块，通信模块包括下位机跟数控装置间的总线从站模块，下位机跟上位机之间的TCP/IP服务器端，上位机的TCP/IP客户端。6. The CNC machine tool failure simulation device according to claim 1, characterized in that the communication module, the communication module includes a bus slave module between the lower computer and the numerical control device, the TCP/IP between the lower computer and the upper computer The server side, the TCP/IP client of the upper computer.
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