CN112729670A - Pneumatic tool wear early warning system and early warning method thereof - Google Patents
Pneumatic tool wear early warning system and early warning method thereof Download PDFInfo
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- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L19/00—Details of, or accessories for, apparatus for measuring steady or quasi-steady pressure of a fluent medium insofar as such details or accessories are not special to particular types of pressure gauges
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- G01L19/12—Alarms or signals
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L19/00—Details of, or accessories for, apparatus for measuring steady or quasi-steady pressure of a fluent medium insofar as such details or accessories are not special to particular types of pressure gauges
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Abstract
The invention discloses a pneumatic tool wear early warning system, which comprises: the first interface piece is connected with a first air pressure interface of the pneumatic tool, the first air pressure sensor acquires real-time working air pressure of the first air pressure interface, the digital-to-analog conversion module carries out analog-to-digital conversion on the real-time working air pressure I of the tool sent by the first air pressure sensor and sends the real-time working air pressure I of the tool to the programmable logic controller, the programmable logic controller enables the real-time working air pressure I of the tool to form a real-time working air pressure curve I of the tool, and the display alarm terminal judges whether tool abrasion early warning is output to the display alarm terminal according to the. The invention also discloses a pneumatic tool wear early warning method. The invention can early warn the working condition that the product or the tool cannot reach the designed position and the product or the tool is damaged due to the abnormal fluctuation of the pressure of the air inlet source and/or the working pressure of the pneumatic tool, thereby avoiding economic loss and providing the practicability and the safety of the high-pneumatic tool.
Description
Technical Field
The invention relates to the field of automobiles, in particular to a pneumatic tool wear early warning system which is used on an automobile production line and takes air pressure as a power source. The invention further relates to a pneumatic tool wear early warning method.
Background
The pneumatic tool is characterized in that the pneumatic tool is a pneumatic tool, and the pneumatic tool is used for driving a pneumatic tool to move in a pneumatic mode. A more conventional application scene of a pneumatic tool on an automobile production line is a processing link of raw materials.
Taking the process of grinding the inner cavity in the production process of a certain part as an example, the action flow is as follows: the pneumatic driving ejector rod pushes the part into the clamp- > the clamp holds the part tightly- > the grinding head stretches into the inner cavity of the part- > the grinding wheel rotates to grind the inner wall of the part. Ideally, the part needs to be snug inside the clamp or the part will be proud of the clamp surface. When the grinding head is pushed into the inner cavity of the part, the grinding head collides with the part, and the grinding wheel is damaged as a result of collision, so that the grinding head is damaged. In the normal production process, the consumption of the grinding wheel is always high, and the grinding head is maintained very frequently. Taking the grinding of the inner cavity of the valve seat of a certain production line as an example, the consumption of the grinding wheel and the maintenance cost of the grinding head even reach more than one million. The deviation of the grinding head during entering can also lead to the reduction of the precision of the machined part. In addition to the grinding process, a plurality of test stations are provided for testing the dynamic and static flow of the fuel injector, such as the fuel injector. Driving the test by the pneumatic power source also causes damage to the test parts of unknown cause. Statistics shows that the damage of the tool driven by the pneumatic power source is usually caused by abnormal work/failure of the pneumatic power source. The abnormality/malfunction of the pneumatic power source is often sporadic and irregular, and is more difficult to be discovered especially in the early stage of the abnormality/malfunction of the pneumatic power source. In addition, in the actual production process, quality monitoring is usually performed only on the machined parts, and the production equipment is overhauled afterwards (after abnormality/fault occurs). Therefore, the early warning of the abrasion of the pneumatic tool is difficult to realize, and the production loss (product loss and production equipment loss) caused by the pneumatic tool is avoided at present.
Disclosure of Invention
The invention aims to provide a pneumatic tool wear early warning system capable of early warning pneumatic tool wear caused by a pneumatic power source.
The invention also provides a pneumatic tool wear early warning method capable of early warning pneumatic tool wear caused by the pneumatic power source.
In order to solve the technical problem, the invention provides a pneumatic tool wear early warning system, which comprises: the device comprises a first interface piece, a first air pressure sensor, an analog-to-digital conversion module, a programmable logic controller and a display alarm terminal;
the first interface piece is connected with a first air pressure interface of a pneumatic tool, the first air pressure sensor acquires real-time working air pressure of the first air pressure interface, the digital-to-analog conversion module performs analog-to-digital conversion on the first real-time working air pressure of the tool sent by the first air pressure sensor and sends the first real-time working air pressure to the programmable logic controller, the programmable logic controller enables the first real-time working air pressure of the tool to form a first real-time working air pressure curve of the tool, and the display alarm terminal judges whether to output tool wear early warning to the display alarm terminal according to the first real-time working air pressure curve.
The air pressure curve is adopted for displaying, so that whether accidental instantaneous air pressure fluctuation occurs or not can be judged more visually, the alarm of the system cannot be triggered if the accidental instantaneous air pressure fluctuation occurs, and the product/equipment loss can be avoided in a manual intervention mode.
Further improve pneumatic frock wearing and tearing early warning system, first atmospheric pressure interface is the pneumatic trigeminy piece interface of pneumatic frock.
In the pneumatic technology, three air source processing elements, namely an air filter (F), a pressure reducing valve (R) and an oil atomizer (L), are assembled together to form a pneumatic triple part, and the pneumatic triple part is used for entering an air source of a pneumatic instrument to be purified, filtered and reduced to the rated air source pressure supplied by the instrument and is equivalent to the function of a power transformer in a circuit. Usually, the pneumatic triplet has an idle interface and can be directly used.
Further improve pneumatic frock wearing and tearing early warning system still includes: a second interface and a second pressure sensor;
the second interface part is connected with a second air pressure interface of the pneumatic tool, the second air pressure sensor collects real-time working air pressure of the second air pressure interface, the digital-to-analog conversion module carries out analog-to-digital conversion on the first real-time working air pressure of the tool and the second real-time working air pressure of the tool sent by the first air pressure sensor and the second air pressure sensor and then sends the converted data to the programmable logic controller, the programmable logic controller respectively forms a first real-time working air pressure curve of the tool and a second real-time working air pressure curve of the tool with the first real-time working air pressure of the tool, and the display alarm terminal judges whether tool abrasion early warning is output to the display alarm terminal according to the first real-time working air pressure curve of the tool and.
The pneumatic tool wear early warning system is further improved, and the second air pressure interface is a pneumatic tool air pressure interface. The second air pressure sensor is connected with an air pressure interface of the pneumatic tool to collect the working air pressure of the pneumatic tool.
The pneumatic tool wear early warning system is further improved, and the display alarm terminal judges whether tool wear early warning is output or not in the following mode;
and if the real-time working air pressure variation quantity of the real-time working air pressure curve is larger than or equal to the preset air pressure variation threshold value, judging that the pneumatic tool is worn, and outputting tool wear early warning.
The working air pressure curve reflects the fluctuation of the air pressure of the air inlet source, and if the real-time working air pressure variation of the air inlet source is larger than or equal to the preset air pressure variation threshold, namely the output air pressure fluctuation of the air pressure power source is too large, unstable driving (too slow or overshoot) can be caused, so that whether the pneumatic tool works abnormally or fails can be judged through the air pressure variation threshold. Particularly, in the initial stage of the abnormal work/fault of the pneumatic tool, the air pressure change is haphazardly, irregularly and instantly generated, the judgment method can effectively predict and judge, and avoid the economic loss caused by the subsequent abnormal work/fault of the pneumatic tool.
The pneumatic tool wear early warning system is further improved, and the display alarm terminal judges whether tool wear early warning is output or not in the following mode;
and if the real-time working air pressure variation quantity of the real-time working air pressure curve is larger than or equal to the preset air pressure variation threshold value, at least twice, judging that the pneumatic tool is worn, and outputting tool wear early warning. By increasing the number of working conditions required for judging the abnormal air pressure, the judgment precision can be prevented from being improved due to misjudgment.
The pneumatic tool wear early warning system is further improved, and the display alarm terminal judges whether tool wear early warning is output or not in the following mode;
and if the real-time working air pressure variation quantity appears on the real-time working air pressure curve and is greater than the preset air pressure variation threshold value within the preset time period, the working condition is at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output. By increasing the number of working conditions required for judging the air pressure abnormality and the number of occurrences of the air pressure abnormality in unit time, the judgment accuracy can be further prevented from being improved due to misjudgment.
The pneumatic tool wear early warning system is further improved, and the display alarm terminal judges whether tool wear early warning is output or not in the following mode;
if the real-time working air pressure curve I or the real-time working air pressure curve II has the real-time working air pressure variation larger than or equal to the preset air pressure variation threshold value, judging that the pneumatic tool is worn, and outputting tool wear early warning. The second working air pressure curve reflects the working air pressure of the pneumatic tool. The real-time working air pressure curve I or the real-time working air pressure curve II can both reflect whether air pressure fluctuation exists in the pneumatic tool, and although the fluctuation reasons may be different, the result hazards caused by the fluctuation reasons are the same. The first working air pressure curve or the second real-time working air pressure curve can realize judgment and early warning, and if the first working air pressure curve or the second real-time working air pressure curve is used in combination, judgment accuracy can be further improved due to misjudgment/missing judgment.
The pneumatic tool wear early warning system is further improved, and the display alarm terminal judges whether tool wear early warning is output or not in the following mode;
and if the real-time working air pressure variation of the real-time working air pressure curve I or the real-time working air pressure curve II is larger than or equal to the preset air pressure variation threshold working condition for at least two times, judging that the pneumatic tool is worn, and outputting tool wear early warning.
The pneumatic tool wear early warning system is further improved, and the display alarm terminal judges whether tool wear early warning is output or not in the following mode;
and if the real-time working air pressure variation of the real-time working air pressure curve I or the real-time working air pressure curve II is greater than the preset air pressure variation threshold value within the preset time period, the working condition is at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
The pneumatic tool wear early warning system is further improved, and the preset time period is 0.1ms-10 ms. As mentioned above, the time of the initial air pressure fluctuation is extremely short, so that the technical effects of avoiding false alarm and avoiding missing alarm can be realized by reasonably selecting the unit time.
Further improving the pneumatic tool wear early warning system, wherein the preset air pressure change threshold is that the air pressure change amount is 100-1000%. The air pressure variation can influence the judgment precision, and the proper air pressure variation is selected, so that false alarm and missing alarm can be avoided.
Further improve pneumatic frock wearing and tearing early warning system, first air pressure sensor gathers precision and is less than or equal to 0.01 bar.
Further improve pneumatic frock wearing and tearing early warning system, second baroceptor collection precision is less than or equal to 0.01 bar.
Because the air pressure fluctuation at the initial stage of the abnormity/fault of the air pressure power source is irregular, the abnormity/fault can be recovered to a normal state very soon after a very short time, and the abnormity/fault is difficult to detect. Therefore, the first and second air pressure sensors with high accuracy are required, which is advantageous for early detection of abnormality/malfunction fluctuation of the pressure power source. Meanwhile, the high-precision sensor is favorable for avoiding false alarm and missing report.
The pneumatic tool wear early warning system is further improved, and the digital-to-analog conversion module is a PLC analog input module.
The pneumatic tool wear early warning system is further improved, and the display alarm terminal is a computer or mobile intelligent equipment. The mobile intelligent device can be a pad or a mobile phone.
The invention provides a pneumatic tool wear early warning method, which comprises the following steps:
1) collecting real-time working air pressure of an air inlet source of a pneumatic tool;
2) if the real-time working air pressure variation of the air inlet source is larger than or equal to the preset air pressure variation threshold working condition, judging the abrasion of the pneumatic tool, and outputting tool abrasion early warning.
And (3) further improving the pneumatic tool wear early warning method, and when the step 2) is implemented, if the working condition of the real-time working air pressure variation of the air inlet source is greater than or equal to a preset air pressure variation threshold value for at least two times, judging that the pneumatic tool is worn and outputting tool wear early warning.
And (3) further improving the pneumatic tool wear early warning method, and when the step 2) is implemented, if the real-time working air pressure variation of the air inlet source is greater than a preset air pressure variation threshold value within a preset time period and at least two times occur, judging that the pneumatic tool is worn and outputting tool wear early warning.
Further improving the pneumatic tool wear early warning method;
1) collecting an air inlet source of a pneumatic tool and real-time working air pressure of the pneumatic tool;
2) if the working condition that the variation of the real-time working air pressure of the air inlet source and/or the variation of the real-time working air pressure of the pneumatic tool is larger than or equal to the preset air pressure variation threshold occurs, judging the abrasion of the pneumatic tool and outputting the early warning of the abrasion of the tool.
The pneumatic tool wear early warning method is further improved, and the display alarm terminal judges whether tool wear early warning is output or not in the following mode;
if the working condition of the real-time working air pressure of the air inlet source and/or the real-time working air pressure variation of the pneumatic tool is larger than or equal to the preset air pressure variation threshold value at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
The pneumatic tool wear early warning method is further improved, and the display alarm terminal judges whether tool wear early warning is output or not in the following mode;
if the working condition that the variation of the real-time working air pressure of the air inlet source and/or the real-time working air pressure of the pneumatic tool is greater than the preset air pressure variation threshold value within the preset time period occurs at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
The pneumatic tool wear early warning method is further improved, and the preset air pressure change threshold is that the air pressure change amount is 100% -1000%.
The pneumatic tool wear early warning method is further improved, and the preset time period is 0.1ms-10 ms.
The invention can at least realize the following technical effects:
1. the invention is a movable early warning system, and the air pressure triple piece of the equipment can be directly connected when needed. Convenient connection, simple operation and high applicability.
2. Real-time recording of the acquisition variables can be realized through Labview, so that whether the equipment is abnormal or not can be analyzed through historical data. The data observation is more intuitive, and the manual access intervention of system false report or missed report is facilitated.
3. The invention has the advantages that the air pressure acquisition is accurate to 0.01bar, the scanning period can reach 1ms, and the problem that the instantaneous change of the air pressure cannot be captured is solved.
4. Through the wireless communication technology and the programming technology, the invention can realize a more flexible display alarm terminal. For example, the most popular mobile phone communication software WeChat is used as an alarm carrier, once a problem occurs, a responsible person can be immediately notified, the delay time does not exceed 1s, the generation of the delay is mainly generated by the time used in network interaction, but the instantaneity of alarm is not influenced in terms of actual use.
5. The yield of the product produced by the pneumatic tool can be improved through pneumatic tool abrasion early warning, non-standard products are avoided, and the loss of parts of the pneumatic tool (such as a grinding head, a grinding wheel and the like) can be reduced.
6. The invention reversely deduces the working state of the equipment through the air pressure change, which is a brand new analysis theory and tool, and pre-judges the abnormity of the air pressure tool through accidental, irregular and instantaneous air pressure change to avoid the condition of products and/or production equipment. Has important practical significance in the industrial 4.0 era of pursuing lean production.
Drawings
The invention will be described in further detail with reference to the following detailed description and accompanying drawings:
fig. 1 is a schematic diagram of a pneumatic tool wear warning system according to a first embodiment of the present invention.
Fig. 2 is a schematic diagram of a pneumatic tool wear warning system according to a fourth embodiment of the present invention.
Detailed Description
The first embodiment of the pneumatic tool wear early warning system provided by the invention comprises the following components: the device comprises a first interface piece, a first air pressure sensor, an analog-to-digital conversion module, a programmable logic controller and a display alarm terminal;
the first interface piece is connected with a pneumatic tool pneumatic triple piece interface, the first air pressure sensor acquires real-time working air pressure of the pneumatic tool pneumatic triple piece interface, the digital-to-analog conversion module performs analog-to-digital conversion on the first tool real-time working air pressure sent by the first air pressure sensor and sends the converted air pressure to the programmable logic controller, the programmable logic controller enables the first tool real-time working air pressure to form a first tool real-time working air pressure curve, and the display alarm terminal judges whether tool wear early warning is output to the display alarm terminal according to the first real-time working air pressure curve.
The display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation quantity of the real-time working air pressure curve is larger than or equal to the preset air pressure variation threshold value, judging that the pneumatic tool is worn, and outputting tool wear early warning.
The digital-to-analog conversion module is a PLC analog input module, and the display alarm terminal is a computer, a pad or a mobile phone. The preset time interval is 0.1ms to 10ms, the preset air pressure change threshold is 100% to 1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%. The acquisition precision of the first air pressure sensor is less than or equal to 0.01bar, and the acquisition precision of the first air pressure sensor is 0.001bar in the embodiment.
The second embodiment of the pneumatic tool wear early warning system provided by the invention comprises the following components: the device comprises a first interface piece, a first air pressure sensor, an analog-to-digital conversion module, a programmable logic controller and a display alarm terminal;
the first interface piece is connected with a pneumatic tool pneumatic triple piece interface, the first air pressure sensor acquires real-time working air pressure of the pneumatic tool pneumatic triple piece interface, the digital-to-analog conversion module performs analog-to-digital conversion on the first tool real-time working air pressure sent by the first air pressure sensor and sends the converted air pressure to the programmable logic controller, the programmable logic controller enables the first tool real-time working air pressure to form a first tool real-time working air pressure curve, and the display alarm terminal judges whether tool wear early warning is output to the display alarm terminal according to the first real-time working air pressure curve.
The display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation quantity of the real-time working air pressure curve is larger than or equal to the preset air pressure variation threshold value, at least twice, judging that the pneumatic tool is worn, and outputting tool wear early warning.
The digital-to-analog conversion module is a PLC analog input module, and the display alarm terminal is a computer, a pad or a mobile phone. The preset time interval is 0.1ms to 10ms, the preset air pressure change threshold is 100% to 1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%. The acquisition precision of the first air pressure sensor is less than or equal to 0.01bar, and the acquisition precision of the first air pressure sensor is 0.005bar in the embodiment.
The third embodiment of the pneumatic tool wear early warning system provided by the invention comprises: the device comprises a first interface piece, a first air pressure sensor, an analog-to-digital conversion module, a programmable logic controller and a display alarm terminal;
the first interface piece is connected with a pneumatic tool pneumatic triple piece interface, the first air pressure sensor acquires real-time working air pressure of the pneumatic tool pneumatic triple piece interface, the digital-to-analog conversion module performs analog-to-digital conversion on the first tool real-time working air pressure sent by the first air pressure sensor and sends the converted air pressure to the programmable logic controller, the programmable logic controller enables the first tool real-time working air pressure to form a first tool real-time working air pressure curve, and the display alarm terminal judges whether tool wear early warning is output to the display alarm terminal according to the first real-time working air pressure curve.
The display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation quantity appears on the real-time working air pressure curve and is greater than the preset air pressure variation threshold value within the preset time period, the working condition is at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
The digital-to-analog conversion module is a PLC analog input module, and the display alarm terminal is a computer, a pad or a mobile phone. The preset time interval is 0.1ms to 10ms, and in this embodiment, 0.1m, 0.2ms, 0.3ms, 0.4ms, 0.5ms, 0.6ms, 0.7ms, 0.8ms, 0.9ms, 1ms, 2ms, 3ms, 4ms, 5ms, 6ms, 7ms, 8ms, 9ms, or 10ms is adopted. The preset air pressure change threshold is 100% -1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%. The acquisition precision of the first air pressure sensor is less than or equal to 0.01bar, and the acquisition precision of the first air pressure sensor is 0.003bar in the embodiment.
The fourth embodiment of the pneumatic tool wear early warning system provided by the invention comprises the following components: the device comprises a first interface piece, a second interface piece, a first air pressure sensor, a second air pressure sensor, an analog-to-digital conversion module, a programmable logic controller and a display alarm terminal;
the first interface piece is connected with a pneumatic tool pneumatic triple piece interface, the first air pressure sensor acquires the real-time working air pressure of the pneumatic tool pneumatic triple piece interface, the second interface piece is connected with a pneumatic tool air pressure interface, the second air pressure sensor acquires the real-time working air pressure of the second air pressure interface, the digital-to-analog conversion module carries out analog-to-digital conversion on the first real-time working air pressure and the second real-time working air pressure of the tool sent by the first air pressure sensor and the second air pressure sensor and then sends the converted result to the programmable logic controller, the programmable logic controller respectively forms a first tool real-time working air pressure curve and a second tool real-time working air pressure curve by using the first tool real-time working air pressure and the second tool real-time working air pressure, and the display alarm terminal judges whether tool wear early warning is output to the display alarm terminal according to the real-time working air pressure curve I and the tool real-time working air pressure curve II.
The display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
if the real-time working air pressure curve I or the real-time working air pressure curve II has the real-time working air pressure variation larger than or equal to the preset air pressure variation threshold value, judging that the pneumatic tool is worn, and outputting tool wear early warning.
The digital-to-analog conversion module is a PLC analog input module, and the display alarm terminal is a computer, a pad or a mobile phone. The preset air pressure change threshold is 100% -1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%. The acquisition accuracy of the first air pressure sensor and the second air pressure sensor is less than or equal to 0.01bar, and the acquisition accuracy of the first air pressure sensor and the second air pressure sensor is 0.01bar in the embodiment.
The fifth embodiment of the pneumatic tooling wear early warning system provided by the invention comprises: the device comprises a first interface piece, a second interface piece, a first air pressure sensor, a second air pressure sensor, an analog-to-digital conversion module, a programmable logic controller and a display alarm terminal;
the first interface piece is connected with a pneumatic tool pneumatic triple piece interface, the first air pressure sensor acquires the real-time working air pressure of the pneumatic tool pneumatic triple piece interface, the second interface piece is connected with a pneumatic tool air pressure interface, the second air pressure sensor acquires the real-time working air pressure of the second air pressure interface, the digital-to-analog conversion module carries out analog-to-digital conversion on the first real-time working air pressure and the second real-time working air pressure of the tool sent by the first air pressure sensor and the second air pressure sensor and then sends the converted result to the programmable logic controller, the programmable logic controller respectively forms a first tool real-time working air pressure curve and a second tool real-time working air pressure curve by using the first tool real-time working air pressure and the second tool real-time working air pressure, and the display alarm terminal judges whether tool wear early warning is output to the display alarm terminal according to the real-time working air pressure curve I and the tool real-time working air pressure curve II.
The display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation of the real-time working air pressure curve I or the real-time working air pressure curve II is larger than or equal to the preset air pressure variation threshold working condition for at least two times, judging that the pneumatic tool is worn, and outputting tool wear early warning.
The digital-to-analog conversion module is a PLC analog input module, and the display alarm terminal is a computer, a pad or a mobile phone. The preset air pressure change threshold is 100% -1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%. The acquisition accuracy of the first air pressure sensor and the second air pressure sensor is less than or equal to 0.01bar, and the acquisition accuracy of the first air pressure sensor and the second air pressure sensor is 0.009bar in the embodiment.
The sixth embodiment of the pneumatic tool wear early warning system provided by the invention comprises the following components: the device comprises a first interface piece, a second interface piece, a first air pressure sensor, a second air pressure sensor, an analog-to-digital conversion module, a programmable logic controller and a display alarm terminal;
the first interface piece is connected with a pneumatic tool pneumatic triple piece interface, the first air pressure sensor acquires the real-time working air pressure of the pneumatic tool pneumatic triple piece interface, the second interface piece is connected with a pneumatic tool air pressure interface, the second air pressure sensor acquires the real-time working air pressure of the second air pressure interface, the digital-to-analog conversion module carries out analog-to-digital conversion on the first real-time working air pressure and the second real-time working air pressure of the tool sent by the first air pressure sensor and the second air pressure sensor and then sends the converted result to the programmable logic controller, the programmable logic controller respectively forms a first tool real-time working air pressure curve and a second tool real-time working air pressure curve by using the first tool real-time working air pressure and the second tool real-time working air pressure, and the display alarm terminal judges whether tool wear early warning is output to the display alarm terminal according to the real-time working air pressure curve I and the tool real-time working air pressure curve II.
The display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation of the real-time working air pressure curve I or the real-time working air pressure curve II is greater than the preset air pressure variation threshold value within the preset time period, the working condition is at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
The digital-to-analog conversion module is a PLC analog input module, and the display alarm terminal is a computer, a pad or a mobile phone. The preset time interval is 0.1ms to 10ms, and in this embodiment, 0.1m, 0.2ms, 0.3ms, 0.4ms, 0.5ms, 0.6ms, 0.7ms, 0.8ms, 0.9ms, 1ms, 2ms, 3ms, 4ms, 5ms, 6ms, 7ms, 8ms, 9ms, or 10ms is adopted. The preset air pressure change threshold is 100% -1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%. The acquisition accuracy of the first air pressure sensor and the second air pressure sensor is less than or equal to 0.01bar, and the acquisition accuracy of the first air pressure sensor and the second air pressure sensor is 0.0001bar in the embodiment.
The invention provides a first embodiment of a pneumatic tool wear early warning method, which comprises the following steps:
1) collecting real-time working air pressure of an air inlet source of a pneumatic tool;
2) if the real-time working air pressure variation of the air inlet source is larger than or equal to the preset air pressure variation threshold working condition, judging the abrasion of the pneumatic tool, and outputting tool abrasion early warning.
The preset air pressure change threshold is 100% -1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%.
The invention provides a second embodiment of a pneumatic tool wear early warning method, which comprises the following steps:
1) collecting real-time working air pressure of an air inlet source of a pneumatic tool;
2) and if the real-time working air pressure variation of the air inlet source is larger than or equal to the preset air pressure variation threshold working condition at least twice, judging the abrasion of the pneumatic tool and outputting tool abrasion early warning.
The preset air pressure variation threshold is an air pressure variation of 100% -1000% (here, the variation is that the air pressure may be increased or decreased, and may be doubled or halved), and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%.
The invention provides a third embodiment of a pneumatic tool wear early warning method, which comprises the following steps:
1) collecting real-time working air pressure of an air inlet source of a pneumatic tool;
2) if the real-time working air pressure variation of the air inlet source is greater than the preset air pressure variation threshold value within the preset time period, at least two times of working conditions occur, the abrasion of the pneumatic tool is judged, and tool abrasion early warning is output.
The preset time interval is 0.1ms to 10ms, and in this embodiment, 0.1m, 0.2ms, 0.3ms, 0.4ms, 0.5ms, 0.6ms, 0.7ms, 0.8ms, 0.9ms, 1ms, 2ms, 3ms, 4ms, 5ms, 6ms, 7ms, 8ms, 9ms, or 10ms is adopted. The preset air pressure change threshold is 100% -1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%.
The invention provides a fourth embodiment of a pneumatic tool wear early warning method, which comprises the following steps:
1) collecting an air inlet source of a pneumatic tool and real-time working air pressure of the pneumatic tool;
2) if the working condition that the variation of the real-time working air pressure of the air inlet source and/or the variation of the real-time working air pressure of the pneumatic tool is larger than or equal to the preset air pressure variation threshold occurs, judging the abrasion of the pneumatic tool and outputting the early warning of the abrasion of the tool.
The preset air pressure change threshold is 100% -1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%.
The invention provides a fifth embodiment of a pneumatic tool wear early warning method, which comprises the following steps:
1) collecting an air inlet source of a pneumatic tool and real-time working air pressure of the pneumatic tool;
2) if the working condition of the real-time working air pressure of the air inlet source and/or the real-time working air pressure variation of the pneumatic tool is larger than or equal to the preset air pressure variation threshold value at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
The preset air pressure change threshold is 100% -1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%.
The invention provides a sixth embodiment of a pneumatic tool wear early warning method, which comprises the following steps:
1) collecting an air inlet source of a pneumatic tool and real-time working air pressure of the pneumatic tool;
2) if the working condition that the variation of the real-time working air pressure of the air inlet source and/or the real-time working air pressure of the pneumatic tool is greater than the preset air pressure variation threshold value within the preset time period occurs at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
The preset time interval is 0.1ms to 10ms, and in this embodiment, 0.1m, 0.2ms, 0.3ms, 0.4ms, 0.5ms, 0.6ms, 0.7ms, 0.8ms, 0.9ms, 1ms, 2ms, 3ms, 4ms, 5ms, 6ms, 7ms, 8ms, 9ms, or 10ms is adopted. The preset air pressure change threshold is 100% -1000% of air pressure change, and the embodiment adopts 100%, 200%, 300%, 400%, 600%, 700%, 800%, 900% or 1000%.
The invention can early warn the working condition that the product or the tool cannot reach the designed position and the product or the tool is damaged due to the abnormal fluctuation of the pressure of the air inlet source and/or the abnormal fluctuation of the pressure of the pneumatic tool, thereby avoiding economic loss and providing the practicability and the safety of the high-pneumatic tool.
The present invention has been described in detail with reference to the specific embodiments and examples, but these are not intended to limit the present invention. Many variations and modifications may be made by one of ordinary skill in the art without departing from the principles of the present invention, which should also be considered as within the scope of the present invention.
Claims (25)
1. The utility model provides a pneumatic frock wearing and tearing early warning system which characterized in that includes: the device comprises a first interface piece, a first air pressure sensor, an analog-to-digital conversion module, a programmable logic controller and a display alarm terminal;
the first interface piece is connected with a first air pressure interface of a pneumatic tool, the first air pressure sensor acquires real-time working air pressure of the first air pressure interface, the digital-to-analog conversion module performs analog-to-digital conversion on the first real-time working air pressure of the tool sent by the first air pressure sensor and sends the first real-time working air pressure to the programmable logic controller, the programmable logic controller enables the first real-time working air pressure of the tool to form a first real-time working air pressure curve of the tool, and the display alarm terminal judges whether to output tool wear early warning to the display alarm terminal according to the first real-time working air pressure curve.
2. The pneumatic tooling wear early warning system of claim 1, characterized in that: the first air pressure interface is a pneumatic triple piece interface of a pneumatic tool.
3. The pneumatic tooling wear early warning system of claim 2, further comprising: a second interface and a second pressure sensor;
the second interface part is connected with a second air pressure interface of the pneumatic tool, the second air pressure sensor acquires the real-time working air pressure of the second air pressure interface, the digital-to-analog conversion module performs analog-to-digital conversion on the first tool real-time working air pressure and the second tool real-time working air pressure which are sent by the first air pressure sensor and the second air pressure sensor and then sends the converted result to the programmable logic controller,
the programmable logic controller respectively forms a first tool real-time working air pressure curve and a second tool real-time working air pressure curve with the first tool real-time working air pressure and the second tool real-time working air pressure curve, and the display alarm terminal judges whether tool wear early warning is output to the display alarm terminal according to the first tool real-time working air pressure curve and the second tool real-time working air pressure curve.
4. The pneumatic tooling wear early warning system of claim 3, wherein: the second air pressure interface is a pneumatic tool air pressure interface.
5. The pneumatic tooling wear early warning system of claim 1, characterized in that: the display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation quantity of the real-time working air pressure curve is larger than or equal to the preset air pressure variation threshold value, judging that the pneumatic tool is worn, and outputting tool wear early warning.
6. The pneumatic tooling wear early warning system of claim 1, characterized in that: the display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation quantity of the real-time working air pressure curve is larger than or equal to the preset air pressure variation threshold value, at least twice, judging that the pneumatic tool is worn, and outputting tool wear early warning.
7. The pneumatic tooling wear early warning system of claim 1, characterized in that: the display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation quantity appears on the real-time working air pressure curve and is greater than the preset air pressure variation threshold value within the preset time period, the working condition is at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
8. The pneumatic tooling wear early warning system of claim 7, wherein: the preset time period is 0.1ms to 10 ms.
9. The pneumatic tooling wear early warning system of claim 3, wherein: the display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
if the real-time working air pressure curve I or the real-time working air pressure curve II has the real-time working air pressure variation larger than or equal to the preset air pressure variation threshold value, judging that the pneumatic tool is worn, and outputting tool wear early warning.
10. The pneumatic tooling wear early warning system of claim 3, wherein: the display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation of the real-time working air pressure curve I or the real-time working air pressure curve II is larger than or equal to the preset air pressure variation threshold working condition for at least two times, judging that the pneumatic tool is worn, and outputting tool wear early warning.
11. The pneumatic tooling wear early warning system of claim 3, wherein: the display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
and if the real-time working air pressure variation of the real-time working air pressure curve I or the real-time working air pressure curve II is greater than the preset air pressure variation threshold value within the preset time period, the working condition is at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
12. The pneumatic tooling wear early warning system of claim 11, wherein: the preset time period is 0.1ms to 10 ms.
13. The pneumatic tooling wear early warning system of any one of claims 3-12, wherein: the preset air pressure change threshold value is that the air pressure change amount is 100% -1000%.
14. The pneumatic tooling wear early warning system of any one of claims 1-12, wherein: the acquisition precision of the first air pressure sensor is less than or equal to 0.01 bar.
15. The pneumatic tooling wear early warning system of claims 3-12, wherein: and the acquisition precision of the second air pressure sensor is less than or equal to 0.01 bar.
16. The pneumatic tooling wear early warning system of any one of claims 1-12, wherein: the digital-to-analog conversion module is a PLC analog input module.
17. The pneumatic tooling wear early warning system of any one of claims 1-12, wherein: the display alarm terminal is a computer or a mobile intelligent device.
18. The pneumatic tool wear early warning method is characterized by comprising the following steps of:
1) collecting real-time working air pressure of an air inlet source of a pneumatic tool;
2) if the real-time working air pressure variation of the air inlet source is larger than or equal to the preset air pressure variation threshold working condition, judging the abrasion of the pneumatic tool, and outputting tool abrasion early warning.
19. The pneumatic tool wear early warning method of claim 18, characterized by comprising: and in the implementation of the step 2), if the real-time working air pressure variation of the air inlet source is larger than or equal to the preset air pressure variation threshold working condition at least twice, judging the abrasion of the pneumatic tool and outputting a tool abrasion early warning.
20. The pneumatic tool wear early warning method of claim 18, characterized by comprising: and in the implementation of the step 2), if the real-time working air pressure variation of the air inlet source is greater than the preset air pressure variation threshold value within the preset time period and at least twice occurs, judging the abrasion of the pneumatic tool and outputting tool abrasion early warning.
21. The pneumatic tool wear early warning method of claim 18, characterized by comprising:
1) collecting an air inlet source of a pneumatic tool and real-time working air pressure of the pneumatic tool;
2) if the working condition that the variation of the real-time working air pressure of the air inlet source and/or the variation of the real-time working air pressure of the pneumatic tool is larger than or equal to the preset air pressure variation threshold occurs, judging the abrasion of the pneumatic tool and outputting the early warning of the abrasion of the tool.
22. The pneumatic tooling wear early warning system of claim 21, wherein: the display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
if the working condition of the real-time working air pressure of the air inlet source and/or the real-time working air pressure variation of the pneumatic tool is larger than or equal to the preset air pressure variation threshold value at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
23. The pneumatic tooling wear early warning system of claim 21, wherein: the display alarm terminal judges whether the tool wear early warning is output or not by adopting the following mode;
if the working condition that the variation of the real-time working air pressure of the air inlet source and/or the real-time working air pressure of the pneumatic tool is greater than the preset air pressure variation threshold value within the preset time period occurs at least twice, the abrasion of the pneumatic tool is judged, and the early warning of the abrasion of the tool is output.
24. The pneumatic tool wear early warning method according to any one of claims 18 to 23, characterized by comprising the following steps: the preset air pressure change threshold value is that the air pressure change amount is 100% -1000%.
25. The pneumatic tool wear early warning method according to claim 20 or 23, characterized in that: the preset time period is 0.1ms to 10 ms.
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| CN202011545887.4A CN112729670A (en) | 2020-12-24 | 2020-12-24 | Pneumatic tool wear early warning system and early warning method thereof |
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Application publication date: 20210430 |