数控机床刀库即时通讯故障诊断系统设计
|
摘要
本文从数控机床维修工作和职业教育远程现场教学的需要出发,以刀库维修作为一点,探索一种远程维修协助PMC、维修现场音视频数据网络即时通讯系统设计。
刀库在数控机床系统中占有重要地位,也是数控机床最容易发生故障的部件,为使刀库可靠运行,保证系统的稳定性,及时发现故障和预防故障发生,为达到此目标,在系统中装设摄像头和信号转接器,以及实时Internet通讯模块,将整个生产线上的数控设备和机床管理站组成上位监控系统,构成现场维修人员、机床管理站和远程专家即时通讯故障诊断系统,实现高效快捷的机床维修管理。
在研究刀库式自动换刀装置PMC控制过程的基础上,根据车间数控机床远程维修协助的需要,就实现机床维修的网络监控,提出网络监控层和现场监控层两层结构,以总线结构作为系统现场网络拓扑结构,用工业以太网技术对现场的网络进行了设计研究。利用Web浏览和公用事业internet网络实现数控机床的远程数据传输,实现数控机床刀库远程维修协助工作。
论文重点对数控机床刀库即时通讯故障诊断系统方案和视频采集方案进行了研究,并在此基础上展开设计。论文提出刀库式自动换刀装置PMC数据采集与网络传输系统结构,并就此进行硬件设计,从而实现PMC数据的网络传输。在刀库维修过程中,有时需要观看刀库动作视频,有时需要定格某个画面,以较高的清晰度观察某个状态。接下来就实现即时通讯远程维修协助系统中采集传输音频和视频,实现现场与远程协助站点数据的互传展开设计。先完成清晰度较高的图片采集与传输,通过对视频传输技术和相关技术分析,通过使用VFW API库函数实现对视频的采集,采用控件嵌入网页的方案设计流程并编程实现基于web的视频远程传输。再利用DirectShow技术,提出即时音频视频实时通讯系统的设计方案,对音视频的实时采集、编码、传输等软件模块进行了设计。最后应用工业以太网将现场数控设备连接,将视频数据通过internet网络上传至远程协助点,从而实现了远程音视频监视与故障协助诊断功能。
This article from the CNC machine maintenance work and vocational education remote field teaching need, starting with a knife as little depot repair, explore a remote maintenance assist PMC, maintenance on-site audio and video data network instant communication system design.
Knife library on the nc machine system occupies an important position, is also the most easily CNC machine parts of the failure, for the sword library and reliable operation, guarantee the stability of system, isolate faults and fault occurs, prevent to reach this goal, in systems installed cameras and adapters, and real-time Internet communication module, the whole line of nc equipment and machine tools data monitoring system, composed upper constitutes a site maintenance personnel, machine data and remote fault diagnosis expert instant messaging system, realize the good efficient machine maintenance management.
In research tool store type automatically change tool device PMC control process, based on the remote maintenance workshop nc machine tools to assist needs, will achieve machine maintenance of network monitor, put forward "network monitoring layer and site monitoring layer" two layers structure to bus structure as the system network topology structure, with the field of industrial Ethernet technology to the scene network design for. Using Web browsing and utilities Internet network realization of CNC remote data transmission, realize CNC machine tool store remote maintenance assistance.
Papers focusing on CNC machine tool store instant communication fault diagnosis system solutions and video collection schemes are studied, and on this basis on design. This paper puts forward that the knife library type automatically change tool device PMC data acquisition and network transmission system structure, and these hardware design, so as to realize the PMC data network transmission. In dao depot repair process, sometimes need to watch video, sometimes knife library action should be stopped a picture, by higher clarity observation of a state. Then achieve instant messaging remote maintenance assistance systems acquisition transmission video and audio,realizing scene with a remote assist site data mutual preach on design. Finish the clarity of higher picture gathering and transmission,video transmission through technology and related technical analysis, through the use of VFW API library function realization of video collection, using control embedded web design process and the programming of the remote transmission based on web video. Reuse DirectShow audio technology, proposed the instant video real-time communication system, the design of the real-time data acquisition of audio and video transmission, coding, software module design. Finally application industrial Ethernet will field numerical control equipment connect,video data through the Internet network will be uploaded to remote assist points,thus achieved a video monitoring and fault to diagnose function.
刀库在数控机床系统中占有重要地位,也是数控机床最容易发生故障的部件,为使刀库可靠运行,保证系统的稳定性,及时发现故障和预防故障发生,为达到此目标,在系统中装设摄像头和信号转接器,以及实时Internet通讯模块,将整个生产线上的数控设备和机床管理站组成上位监控系统,构成现场维修人员、机床管理站和远程专家即时通讯故障诊断系统,实现高效快捷的机床维修管理。
在研究刀库式自动换刀装置PMC控制过程的基础上,根据车间数控机床远程维修协助的需要,就实现机床维修的网络监控,提出网络监控层和现场监控层两层结构,以总线结构作为系统现场网络拓扑结构,用工业以太网技术对现场的网络进行了设计研究。利用Web浏览和公用事业internet网络实现数控机床的远程数据传输,实现数控机床刀库远程维修协助工作。
论文重点对数控机床刀库即时通讯故障诊断系统方案和视频采集方案进行了研究,并在此基础上展开设计。论文提出刀库式自动换刀装置PMC数据采集与网络传输系统结构,并就此进行硬件设计,从而实现PMC数据的网络传输。在刀库维修过程中,有时需要观看刀库动作视频,有时需要定格某个画面,以较高的清晰度观察某个状态。接下来就实现即时通讯远程维修协助系统中采集传输音频和视频,实现现场与远程协助站点数据的互传展开设计。先完成清晰度较高的图片采集与传输,通过对视频传输技术和相关技术分析,通过使用VFW API库函数实现对视频的采集,采用控件嵌入网页的方案设计流程并编程实现基于web的视频远程传输。再利用DirectShow技术,提出即时音频视频实时通讯系统的设计方案,对音视频的实时采集、编码、传输等软件模块进行了设计。最后应用工业以太网将现场数控设备连接,将视频数据通过internet网络上传至远程协助点,从而实现了远程音视频监视与故障协助诊断功能。
This article from the CNC machine maintenance work and vocational education remote field teaching need, starting with a knife as little depot repair, explore a remote maintenance assist PMC, maintenance on-site audio and video data network instant communication system design.
Knife library on the nc machine system occupies an important position, is also the most easily CNC machine parts of the failure, for the sword library and reliable operation, guarantee the stability of system, isolate faults and fault occurs, prevent to reach this goal, in systems installed cameras and adapters, and real-time Internet communication module, the whole line of nc equipment and machine tools data monitoring system, composed upper constitutes a site maintenance personnel, machine data and remote fault diagnosis expert instant messaging system, realize the good efficient machine maintenance management.
In research tool store type automatically change tool device PMC control process, based on the remote maintenance workshop nc machine tools to assist needs, will achieve machine maintenance of network monitor, put forward "network monitoring layer and site monitoring layer" two layers structure to bus structure as the system network topology structure, with the field of industrial Ethernet technology to the scene network design for. Using Web browsing and utilities Internet network realization of CNC remote data transmission, realize CNC machine tool store remote maintenance assistance.
Papers focusing on CNC machine tool store instant communication fault diagnosis system solutions and video collection schemes are studied, and on this basis on design. This paper puts forward that the knife library type automatically change tool device PMC data acquisition and network transmission system structure, and these hardware design, so as to realize the PMC data network transmission. In dao depot repair process, sometimes need to watch video, sometimes knife library action should be stopped a picture, by higher clarity observation of a state. Then achieve instant messaging remote maintenance assistance systems acquisition transmission video and audio,realizing scene with a remote assist site data mutual preach on design. Finish the clarity of higher picture gathering and transmission,video transmission through technology and related technical analysis, through the use of VFW API library function realization of video collection, using control embedded web design process and the programming of the remote transmission based on web video. Reuse DirectShow audio technology, proposed the instant video real-time communication system, the design of the real-time data acquisition of audio and video transmission, coding, software module design. Finally application industrial Ethernet will field numerical control equipment connect,video data through the Internet network will be uploaded to remote assist points,thus achieved a video monitoring and fault to diagnose function.
引文
[1]Trajkovski,S. AUTOMATIC TOOL CHANGERS FOR NC MACHINING CENTRES[J]. Springer-Verlag,1985.10:95-100.
[2]Yencha, Mitch. Automatic tool changer gives robots more flexibility[J]. Welding Design and Fabrication,2003.02:22.
[3]邱煜城.刀库之发展趋势与未来展望[J].制造技术与机床,2007,04：114.
[4]E. Niemi, Optimal tool magazine operation[J]. Int J Adv ManufTechnol, 2004.24:567-572.
[5]Park, Sang Min, An, Jong Suk, Rye, Beom-Sahng. The development of automatic tool changer and integrated applications software for polishing robot system[J].Proceedings of the 1ASTED International Conference OB Robotics and Applications,2003:67-172.
[6]博弈创作室.ANSYS9.0经典产品基础教程与实例详解[M].北京：中国水利水电出版社,2006：39.353.
[7]李一民.数控机床.南京：东南大学出版社,2005.
[8]黄明吉.虚拟数控技术及应用.北京：化学工业出版社,2005.
[9]李雪梅.数控机床.北京：电子工业出版社,2005.
[10]杨有君.数控技术.北京：机械工业出版社,2005
[11]余英良.数控加工编程及操作.北京：高等教育出版社,2005.
[12]田萍.数控机床加工工艺及设备.北京：电子工业出版社,2005.
[13]天津市机电工业控股集团公司,天津机电职业技术学院主编.高级加工中心操作工.天津：天津科学技术出版杜,2004.
[14]刘建慧,邹慧君.加工中心自动换刀装置类型综述及设计特点.机械设计与研究,2001.17(3)：49-51.
[15]王爱玲.数控机床加工工艺.北京：机械工业出版社,2006.
[16]王爱玲.数控机床结构及应用.北京：机械工业出版社,2006.
[17]王志平.机床数控技术应用.北京：高等教育出版社,1998.
[[8]曹秋霞.小型立式加工中心无机械手自动换刀装置的设计.机床与液压,2006.9：54-57.
[19]赵葛霄,黄玉辉.加工中心的自动换刀方式及PC实现方法.现代机械.2001,2：6-10.
[20]张楠,李强,秦建国.斗笠式刀库换刀过程的控制.信息技术.2006,4：106-107.
[21]向金林.TH7130立式加工中心自动换刀系统的设计.装备制造技术.2006,3：7-9.
[22]文怀兴,夏田.数控机床系统设计.北京：化学工业出版社,2005.
[23]小堀洋一,长泽总,清水秀行,佐佐木正光.数控机床的监视系统.http:/www.patent-cn.com/G06F/CN1108407.shtml.
[24]鲁方霞,邓朝晖.数控机床的发展趋势及国内发展现状,2006.40：44-46.
[25]丁庆新,焦汝娟,李晓俭.数控机床远程监视与故障诊断系统.电气时代,2004(2)：110-111.
[26]沈航等.工业以太网和现场总线.工业仪表与自动化装置,2005.1.
[27]冯晓东等.工业以太网技术及应用前景.电子产品世界,2004.12.
[28]陆明浩.现场总线的发展趋向-工业以太网的应用.智能建筑与城市信息,2004.10.
[29]Pennebaker. W. B,and J. L. Mitchell. JPEG still image data compression standard. Standford University,1993.
[30]黄湛,龙伟.远程视频技术在网络数控加工监控中的应用.机械,2002.29(2)：76-78.
[31]精英科技.视频压缩与音频编码技术.北京：中国电力出版社,2001.53.
[32]李为民,潘卫东,梁济仁.实现视频捕获和显示的简易方法,实验科学与技术,2007(2)：44-46
[33]王振宇,江崇民,李德秀.快速可靠的自动换刀机构[J].机械工程师.2006.4：132
[34]陈芳,李继中.Automatic tool changer system control of machine center with carousal storage [J].机械设计与制造,2007.10：25.26.
[35]刘炜.数控加工中心自动换刀系统[J].机床与液压,2005,05：85.
[36]Gokler, Mustafa Ilhan Koc Murat Bilgin. Design of an automatic tool changer with disc magazine for a CNC horizontal machining centerEJ]. Internationfl Journfl of Machine Tools&Manufacture,1997.03:58-60.
[37]万会雄,明仁雄.液压与气压传动[M].北京：国防工业出版社,2008：1-6.
[38]Yan, H. S. Methodology for the configuration synthesis of machining centers with automatic tool changer[J]. Journfl of Mechanical Design, Transactions of the ASME,1999.09:359-367.
[39]向金林.TH7130立式加工中心自动换刀系统的设计[J].装备制造技术,2006.03：7-9.
[40]郑俊,许明恒,高宏力等.PCB钻床自动换刀机械手换刀部分的设计分析[J].现代机械.2008.01：6-7.
[41]刘建慧,邹慧君,颜洪森.对加工中心自动换刀装置换刀时间的探讨[J].组合机床与自动化加工技术,2004.08：35.36.
[42]王科社,扬庆东,张怀存.关于自动换刀装置速度和可靠性提高的讨论[J].机械,2002,81：92.93.
[43]王科社,盛伯浩.自动换刀装置换刀时间计量方法[J].组合机床与自动化加工技术,2001.04：21.22
[44]安海峰.谈高速加工中心的快速自动换刀技术[J].中国新技术新产品,2008.09：91
[45]戚洪利.自动换刀装置及其控制的研究[D].兰州：兰州理工大学,2007.6.15.
[46]黄泽正,刘冲,陈志辉.Design of Automatic Tool Changer for Machine Center [J].机械工程与自动化,2007.01：11.13.
[47]Ryuh, Beom-Sahn Park, Sang MiIl, Pennock'Gordon. An automatic tool changer and integrated software for a robotic die polishing station[J]. Mechanism and Machine Theory,2006.04:415-432.
[48]杨本娟.基于小波技术的实时视频教育系统(W-RVES)的研究与设计.学位论文.贵州大学,2007.P43-53.
[49]陈春华,黄元庆.基于DirectShow的多媒体应用开发技术.莆田学院学报,2005.12(5)：65-68.
[50]郑鸿,陈青山,张文渊,DirectShow的原理及其应用.微型电脑应用,2001.17(8)：41-42.62.
[51]陆其明.DirectShow开发指南.北京：清华人学出版社,2003.230-246.
[52]黄振宇,王敏,吴涛.基于C0M的Directshow Filter实现.微机发展,2004.14(5)：113-116.
[53]庄严,李世收,陆小华.一种基于DirectShow的实时视频传输实现方法.南京工业大学学报,2004.26(6)：85-89.
[54]刘平,商胜法,王金富.一种基丁：DirectShow COM接口的多媒体流解码程序的设计.山东科技,2002.15(3)：17-21.
[55]田春霞.基于虚拟现实的刀库换刀教学系统研究与实现[D].学位论文.大连理工大学,2007.
[56]陈芳.PMC在加工中心随机自动换刀中的应用.机电工程技术,2004.(33).
[57]裴旭明等.基于PLC控制的加工中心随机换刀方式研究.设备设计与维修,2004 (8).
[58]黄菊生等.基于1PG定位模块的刀库控制技术.湖南工程学院.2009(39卷/8期P62-65).
[59]胡峰松.基于IP的多媒体网络教学系统的研究与开发.现代计算机,2000.83：24-27.
[60]周建东.加工中心盘式刀库的设计.工艺与装备,2007(8).84.
[2]Yencha, Mitch. Automatic tool changer gives robots more flexibility[J]. Welding Design and Fabrication,2003.02:22.
[3]邱煜城.刀库之发展趋势与未来展望[J].制造技术与机床,2007,04：114.
[4]E. Niemi, Optimal tool magazine operation[J]. Int J Adv ManufTechnol, 2004.24:567-572.
[5]Park, Sang Min, An, Jong Suk, Rye, Beom-Sahng. The development of automatic tool changer and integrated applications software for polishing robot system[J].Proceedings of the 1ASTED International Conference OB Robotics and Applications,2003:67-172.
[6]博弈创作室.ANSYS9.0经典产品基础教程与实例详解[M].北京：中国水利水电出版社,2006：39.353.
[7]李一民.数控机床.南京：东南大学出版社,2005.
[8]黄明吉.虚拟数控技术及应用.北京：化学工业出版社,2005.
[9]李雪梅.数控机床.北京：电子工业出版社,2005.
[10]杨有君.数控技术.北京：机械工业出版社,2005
[11]余英良.数控加工编程及操作.北京：高等教育出版社,2005.
[12]田萍.数控机床加工工艺及设备.北京：电子工业出版社,2005.
[13]天津市机电工业控股集团公司,天津机电职业技术学院主编.高级加工中心操作工.天津：天津科学技术出版杜,2004.
[14]刘建慧,邹慧君.加工中心自动换刀装置类型综述及设计特点.机械设计与研究,2001.17(3)：49-51.
[15]王爱玲.数控机床加工工艺.北京：机械工业出版社,2006.
[16]王爱玲.数控机床结构及应用.北京：机械工业出版社,2006.
[17]王志平.机床数控技术应用.北京：高等教育出版社,1998.
[[8]曹秋霞.小型立式加工中心无机械手自动换刀装置的设计.机床与液压,2006.9：54-57.
[19]赵葛霄,黄玉辉.加工中心的自动换刀方式及PC实现方法.现代机械.2001,2：6-10.
[20]张楠,李强,秦建国.斗笠式刀库换刀过程的控制.信息技术.2006,4：106-107.
[21]向金林.TH7130立式加工中心自动换刀系统的设计.装备制造技术.2006,3：7-9.
[22]文怀兴,夏田.数控机床系统设计.北京：化学工业出版社,2005.
[23]小堀洋一,长泽总,清水秀行,佐佐木正光.数控机床的监视系统.http:/www.patent-cn.com/G06F/CN1108407.shtml.
[24]鲁方霞,邓朝晖.数控机床的发展趋势及国内发展现状,2006.40：44-46.
[25]丁庆新,焦汝娟,李晓俭.数控机床远程监视与故障诊断系统.电气时代,2004(2)：110-111.
[26]沈航等.工业以太网和现场总线.工业仪表与自动化装置,2005.1.
[27]冯晓东等.工业以太网技术及应用前景.电子产品世界,2004.12.
[28]陆明浩.现场总线的发展趋向-工业以太网的应用.智能建筑与城市信息,2004.10.
[29]Pennebaker. W. B,and J. L. Mitchell. JPEG still image data compression standard. Standford University,1993.
[30]黄湛,龙伟.远程视频技术在网络数控加工监控中的应用.机械,2002.29(2)：76-78.
[31]精英科技.视频压缩与音频编码技术.北京：中国电力出版社,2001.53.
[32]李为民,潘卫东,梁济仁.实现视频捕获和显示的简易方法,实验科学与技术,2007(2)：44-46
[33]王振宇,江崇民,李德秀.快速可靠的自动换刀机构[J].机械工程师.2006.4：132
[34]陈芳,李继中.Automatic tool changer system control of machine center with carousal storage [J].机械设计与制造,2007.10：25.26.
[35]刘炜.数控加工中心自动换刀系统[J].机床与液压,2005,05：85.
[36]Gokler, Mustafa Ilhan Koc Murat Bilgin. Design of an automatic tool changer with disc magazine for a CNC horizontal machining centerEJ]. Internationfl Journfl of Machine Tools&Manufacture,1997.03:58-60.
[37]万会雄,明仁雄.液压与气压传动[M].北京：国防工业出版社,2008：1-6.
[38]Yan, H. S. Methodology for the configuration synthesis of machining centers with automatic tool changer[J]. Journfl of Mechanical Design, Transactions of the ASME,1999.09:359-367.
[39]向金林.TH7130立式加工中心自动换刀系统的设计[J].装备制造技术,2006.03：7-9.
[40]郑俊,许明恒,高宏力等.PCB钻床自动换刀机械手换刀部分的设计分析[J].现代机械.2008.01：6-7.
[41]刘建慧,邹慧君,颜洪森.对加工中心自动换刀装置换刀时间的探讨[J].组合机床与自动化加工技术,2004.08：35.36.
[42]王科社,扬庆东,张怀存.关于自动换刀装置速度和可靠性提高的讨论[J].机械,2002,81：92.93.
[43]王科社,盛伯浩.自动换刀装置换刀时间计量方法[J].组合机床与自动化加工技术,2001.04：21.22
[44]安海峰.谈高速加工中心的快速自动换刀技术[J].中国新技术新产品,2008.09：91
[45]戚洪利.自动换刀装置及其控制的研究[D].兰州：兰州理工大学,2007.6.15.
[46]黄泽正,刘冲,陈志辉.Design of Automatic Tool Changer for Machine Center [J].机械工程与自动化,2007.01：11.13.
[47]Ryuh, Beom-Sahn Park, Sang MiIl, Pennock'Gordon. An automatic tool changer and integrated software for a robotic die polishing station[J]. Mechanism and Machine Theory,2006.04:415-432.
[48]杨本娟.基于小波技术的实时视频教育系统(W-RVES)的研究与设计.学位论文.贵州大学,2007.P43-53.
[49]陈春华,黄元庆.基于DirectShow的多媒体应用开发技术.莆田学院学报,2005.12(5)：65-68.
[50]郑鸿,陈青山,张文渊,DirectShow的原理及其应用.微型电脑应用,2001.17(8)：41-42.62.
[51]陆其明.DirectShow开发指南.北京：清华人学出版社,2003.230-246.
[52]黄振宇,王敏,吴涛.基于C0M的Directshow Filter实现.微机发展,2004.14(5)：113-116.
[53]庄严,李世收,陆小华.一种基于DirectShow的实时视频传输实现方法.南京工业大学学报,2004.26(6)：85-89.
[54]刘平,商胜法,王金富.一种基丁：DirectShow COM接口的多媒体流解码程序的设计.山东科技,2002.15(3)：17-21.
[55]田春霞.基于虚拟现实的刀库换刀教学系统研究与实现[D].学位论文.大连理工大学,2007.
[56]陈芳.PMC在加工中心随机自动换刀中的应用.机电工程技术,2004.(33).
[57]裴旭明等.基于PLC控制的加工中心随机换刀方式研究.设备设计与维修,2004 (8).
[58]黄菊生等.基于1PG定位模块的刀库控制技术.湖南工程学院.2009(39卷/8期P62-65).
[59]胡峰松.基于IP的多媒体网络教学系统的研究与开发.现代计算机,2000.83：24-27.
[60]周建东.加工中心盘式刀库的设计.工艺与装备,2007(8).84.